Market Position:
The Polaris Sportsman series is a cornerstone in the utility ATV market, known for its robust performance, comfort, and off-road capability. This manual serves owners and technicians who rely on their ATVs for work or recreation.
Competitive Analysis:
Competes with models from brands like Can-Am (Outlander), Honda (Foreman, Rubicon), Yamaha (Grizzly), and Suzuki (KingQuad). The Sportsman often distinguishes itself with its independent suspension and comfortable ride.
Key Features:
Focus on detailed, accurate repair procedures for reliable maintenance and restoration of Polaris Sportsman 400 and 500 models.
Coverage Areas:
Complete Service, Repair, and Workshop Manual
Page Count:
Extensive (exact count not specified, but implied to be comprehensive)
Manual Type:
Service Repair Workshop Manual
Engine Systems:
Engine disassembly, assembly, overhaul, lubrication, cooling, fuel, ignition, starting, charging systems.
Drivetrain Systems:
Transmission, clutch, drive shafts, differential, final drive, AWD system (if applicable).
Suspension Steering:
Front and rear suspension components, shocks, springs, steering linkage, steering column, steering rack/gearbox.
Braking Systems:
Hydraulic brake system, brake calipers, brake pads, brake rotors, master cylinder, brake lines, parking brake.
Electrical Systems:
Wiring diagrams, battery, charging system, starter, lighting, ignition switch, fuses, relays, instrumentation.
Body Frame:
Frame construction, body panels, fenders, racks, seat, handlebars, plastics.
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, spark plug maintenance, fluid checks and top-offs.
Troubleshooting Guides:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts.
Repair Procedures:
Step-by-step instructions for component removal, replacement, and reassembly.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Technical Depth:
Comprehensive: From basic maintenance and adjustments to complete engine and transmission rebuilds, electrical diagnostics, and chassis repair.
Engine Type 400:
4-stroke, SOHC, 2-valve, Single Cylinder
Engine Displacement 400:
Approx. 375cc - 400cc (varies by specific model year)
Engine Type 500:
4-stroke, SOHC, 2-valve, Single Cylinder
Engine Displacement 500:
Approx. 499cc - 500cc (varies by specific model year)
Horsepower Range:
Varies by model year and engine, typically in the 25-35 HP range.
Torque Range:
Varies by model year and engine, focusing on low-end torque for utility.
Fuel Delivery:
Carbureted (e.g., Mikuni, Keihin) or Electronic Fuel Injection (EFI) depending on model year.
Fuel Type:
Unleaded gasoline
Ignition Type:
Electronic ignition (CDI or ECU controlled)
Cooling Method:
Liquid-cooled (radiator and fan)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Transmission Gears:
High, Low, Neutral, Reverse, Park (with engine braking)
Optional Transmission:
N/A (CVT is standard)
Cvta Operation:
Detailed explanation of CVT operation, belt inspection, and replacement procedures.
Drive Modes:
2WD / 4WD selectable (often on-the-fly with electronic activation).
Transmission Fluid Type:
Specific CVT fluid (e.g., Polaris AGL or equivalent, manual will specify exact type and change intervals).
Length:
Varies by model year, typically around 80-83 inches.
Width:
Varies by model year, typically around 46-48 inches.
Height:
Varies by model year, typically around 47-50 inches.
Wheelbase:
Varies by model year, typically around 50-52 inches.
Dry Weight:
Varies by model year and configuration, typically between 600-700 lbs.
Ground Clearance:
Varies by model year, typically around 8-12 inches.
Front Rack Capacity:
Typically around 50 lbs.
Rear Rack Capacity:
Typically around 100 lbs.
Towing Capacity:
Typically around 1,500 lbs.
Safety Ratings:
N/A (ATVs are not subject to the same passenger vehicle safety ratings like NHTSA or IIHS; safety focus is on operational design).
Active Safety:
Engine braking, stable chassis design, responsive steering, reliable brake system.
Passive Safety:
Hand guards, comfortable seating position, integrated lighting.
Operational Warnings:
Manual will detail critical safety warnings for operation, including use of PPE, riding conditions, and load limits.
Infotainment System:
Basic; typically includes analog/digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and indicator lights.
Driver Assistance Features:
Limited; primary focus on mechanical and electrical systems. Some models may feature electronic fuel injection (EFI) for improved performance and fuel efficiency.
Connectivity:
N/A (No integrated digital connectivity features like Bluetooth or GPS typically found on models covered by this manual).
Initial Service:
First service typically around 20-50 hours or 1 month, covering oil change, filter check, and general inspection.
Regular Maintenance Intervals:
Routine checks and lubrication every 50-100 hours, with more comprehensive services (e.g., valve adjustment, transmission service) at longer intervals (e.g., 300-500 hours).
Spark Plug Replacement:
Typically recommended every 100-200 hours or annually.
Engine Oil Type:
Specific Polaris synthetic engine oil or equivalent meeting API SG, SH, SJ, or higher specifications. Viscosity typically SAE 0W-40 or 5W-50 depending on operating temperature.
Engine Oil Capacity:
Approximately 2.0-2.5 quarts (refer to manual for exact capacity).
Coolant Type:
Ethylene glycol based antifreeze/coolant with corrosion inhibitors (e.g., Polaris brand or equivalent meeting specified standards).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will specify).
Known Issues:
Potential for CV joint wear, starter motor issues, charging system problems (stator/regulator), and CVT belt wear/failure. Manual provides diagnostic steps for these.
Common Filter Part Numbers:
Manual will list specific OEM part numbers for oil filters, air filters, and fuel filters for various model years.
Brand Heritage:
Polaris Industries is a long-standing American manufacturer of powersports vehicles, known for its innovation in ATVs and snowmobiles since its founding in 1954.
Model Evolution:
The Sportsman line has been a flagship model, continuously evolving with technological advancements, engine improvements, and chassis updates since its introduction.
Production Years:
The Sportsman 400 and 500 have been in production across various iterations and updates from the late 1990s through the 2010s, with specific manual coverage likely spanning a significant portion of this range.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Recognitions:
The Polaris Sportsman line has consistently received positive reviews and industry accolades for its comfort, handling, and utility capabilities over the years.
User Ratings:
Owner satisfaction is generally high due to reliability and performance in its class.
Certifications:
Manufactured to meet relevant industry standards and emissions regulations for ATVs in its operating markets.
