Segment:
Mid-size utility ATV, popular for trail riding, hunting, and general farm work.
Key Competitors:
Yamaha Kodiak, Honda Foreman, Can-Am Outlander.
Powertrain:
Torquey Polaris 4-stroke engine known for its reliable performance in its class.
Transmission:
Polaris Variable Transmission (PVT) for automatic operation and engine braking.
Suspension Type:
Independent front and rear suspension for a comfortable ride and good ground clearance.
Drive System:
On-Demand All-Wheel Drive (AWD) system providing excellent traction.
Engine:
Detailed diagnostics, repair, and overhaul procedures for 4-stroke engines.
Fuel System:
Carburetor (likely Mikuni BSR series for 400/500 models), fuel pump, fuel lines, and tank maintenance.
Ignition System:
CDI unit, ignition coils, spark plugs, timing checks, and troubleshooting.
Drivetrain:
PVT (Polaris Variable Transmission) clutch system (primary and secondary), belt inspection and replacement, gearcase, drive shafts, and CV joints.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, bushings, and alignment procedures.
Brakes:
Hydraulic brake system, calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter, and accessory circuits.
Cooling System:
Radiator, coolant, fan operation, hoses, and thermostat.
Steering:
Handlebar assembly, tie rods, steering shaft, and potential for EPS (Electronic Power Steering) if applicable to specific trims.
Bodywork:
Fenders, racks, seat, plastic panels, and fairings removal and installation.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, and lubrication points.
Troubleshooting:
Diagnostic flowcharts for common starting, running, and electrical issues.
Engine Rebuild:
Top-end and bottom-end engine overhauls, piston, ring, and cylinder inspection/replacement.
Transmission Service:
PVT belt replacement, clutch assembly inspection and service, gearcase fluid changes.
Brake System Service:
Pad replacement, caliper service, line flushing, and bleeding.
Electrical Diagnostics:
Component testing, wiring harness repair, and troubleshooting electrical faults using provided diagrams.
Suspension Repair:
Shock absorber replacement, bushing inspection and replacement, and bearing service.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission overhauls.
Diagnostic Level:
Advanced, including fault codes (if applicable), wiring diagrams, and troubleshooting guides.
Repair Level:
Full workshop level, suitable for professional mechanics and experienced DIYers.
Engine Type:
4-stroke, liquid-cooled, SOHC (Single Overhead Cam)
Engine Displacement 400:
375cc (approx.)
Engine Displacement 500:
499cc (approx.)
Bore X Stroke 400:
Specifics available in manual (e.g., ~83mm x 71.4mm)
Bore X Stroke 500:
Specifics available in manual (e.g., ~92mm x 77mm)
Compression Ratio:
Typically around 9.2:1 to 10.0:1 (details in manual)
Horsepower 400:
Approx. 25-28 HP (specific figures vary)
Horsepower 500:
Approx. 30-33 HP (specific figures vary)
Torque 400:
Approx. 27-30 lb-ft (specific figures vary)
Torque 500:
Approx. 32-35 lb-ft (specific figures vary)
Fuel Delivery:
Carburetor (likely Mikuni BSR series)
Fuel Type:
Unleaded gasoline, 87 octane minimum recommended.
Fuel Tank Capacity:
Approximately 3.25 US gallons (12.3 Liters).
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first (refer to manual for exact specification).
Spark Plug Replacement:
Check/replace every 50-100 hours or annually.
Air Filter Cleaning:
Inspect every 25-50 hours, clean or replace as needed.
Transmission Belt Inspection:
Inspect every 50 hours for wear and damage.
Engine Oil Type:
Polaris recommends specific synthetic or semi-synthetic engine oil meeting API classifications (e.g., SAE 0W-40 or 10W-40, check manual for exact spec).
Engine Oil Capacity:
Approx. 1.7 US quarts (1.6 Liters) with filter change (verify in manual).
Gearcase Oil Type:
Polaris Synthetic Gearcase Lubricant or equivalent SAE 75W-90.
Gearcase Oil Capacity:
Approx. 0.25 US quarts (0.24 Liters) (verify in manual).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water).
Pvtturbos Wear:
PVT belt wear and clutch sheave wear can occur with aggressive use or improper maintenance.
Electrical Connectors:
Some earlier Polaris models experienced issues with corrosion or looseness in electrical connectors; a thorough inspection is recommended.
Carburetor Tuning:
Carburetors may require adjustment due to altitude or fuel variations; proper jetting is crucial.
