Segment:
Recreational and utility ATV, dual-seat touring configuration.
Target Audience:
Enthusiast riders, recreational users, owners seeking to perform maintenance and repairs.
Key Competitors:
Can-Am Outlander Max, Arctic Cat TRV, Yamaha Grizzly, Honda FourTrax Foreman/Rubicon (touring variants).
Touring Design:
Designed for comfortable two-up riding with a passenger seat and integrated backrest/handles.
Engine Performance:
Powerful 500cc HO (High Output) engine offering strong low-end torque and reliable performance for various terrains.
Suspension Comfort:
Independent front and rear suspension designed for a smoother ride over rough terrain, enhancing touring comfort.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, fuel delivery, ignition, starting, charging, emissions control.
Drivetrain Systems:
Transmission (PVT - Polaris Variable Transmission), drive shafts, differentials (front and rear), AWD system (On-Demand), final drive units, clutch operation and service.
Chassis And Suspension:
Frame inspection and repair, front and rear suspension geometry, shock absorbers, springs, bushings, ball joints, control arms, steering system (rack and pinion), wheel bearings.
Electrical Systems:
Wiring diagrams, battery, alternator, starter motor, lighting systems (headlights, taillights, brake lights), ignition system components, instrument cluster, sensors, EFI control unit (ECU) troubleshooting.
Braking Systems:
Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, rotors, bleeding procedure, parking brake mechanism.
Body And Trim:
Body panel removal and installation, fenders, racks, seat, lighting covers, decals.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, valve clearance adjustment.
Troubleshooting Diagnostics:
Systematic troubleshooting flowcharts for common issues, fault code interpretation (if applicable), diagnostic procedures for engine, electrical, and drivetrain problems.
Major Repairs:
Engine rebuild procedures, transmission overhaul, differential repair, suspension component replacement, steering system overhaul, brake system component replacement.
Technical Specifications:
Torque specifications for all fasteners, fluid capacities, electrical specifications, engine timing, compression test procedures, wheel alignment data.
Special Tools:
Identification and usage instructions for specialized tools required for specific service procedures.
Diagnostic Level:
Advanced diagnostics including sensor testing, ECU signal analysis, and fault code reading/clearing.
Rebuild Level:
Complete engine and transmission overhaul procedures, including detailed part descriptions and assembly sequences.
Calibration And Adjustment:
Procedures for tuning, carburetor adjustment (if applicable, though these models are typically EFI), and electrical system calibration.
Engine Type:
4-stroke, SOHC, 4-valve, Single Cylinder
Bore X Stroke:
92.0 mm x 75.0 mm (typical for this engine family)
Cooling System:
Liquid-cooled
Lubrication System:
Wet sump
Horsepower:
Approx. 32 HP @ 6500 RPM (estimated, specific figures may vary by model year)
Torque:
Approx. 30 lb-ft @ 5000 RPM (estimated)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum recommended
Ignition Type:
CDI (Capacitor Discharge Ignition) with electronic advance
Safety Certification:
ATV Safety Institute (ASI) recommended practices; CPSC (Consumer Product Safety Commission) compliant for recreational off-highway vehicles.
Braking System:
Hydraulic disc brakes front and rear with sealed systems.
Engine Braking:
Integrated into the PVT system for controlled descents.
Afr System:
Active Descent Control (ADC) - may be present on some specific configurations for enhanced downhill control.
Lighting:
Dual 50W headlights, dual taillights/stop lights.
Passenger Comfort:
Ergonomic passenger seat with backrest and handgrips for improved rider and passenger safety and comfort.
Throttle Limiter:
Thumb throttle with a limit screw is standard for adjustable throttle control.
Instrument Cluster:
Digital instrument cluster with speedometer, tachometer, odometer, trip meter, fuel gauge, engine hour meter, AWD indicator, and gear position indicator.
Charging System:
12V DC outlet for charging accessories (location may vary).
Efi:
Electronic Fuel Injection (EFI) for improved throttle response, fuel efficiency, and cold-weather starting.
AWD System:
Polaris' On-Demand AWD system automatically engages the front drive when rear wheel slippage is detected.
Diagnostic Ports:
Access to diagnostic connectors for EFI system analysis (detailed in manual).
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first).
Air Filter Inspection:
Every 25 hours or monthly.
Spark Plug Inspection And Replacement:
Inspect every 100 hours, replace as needed (typical NGK spark plug).
Transmission Fluid Change:
Every 100 hours or annually.
Engine Oil Type:
SAE 5W-50 synthetic (Polaris recommended) or API CI-4 rated diesel engine oil.
Engine Oil Capacity:
Approx. 2.7 quarts (2.5 liters) with filter change.
Transmission Fluid Type:
Polaris Demand Drive Fluid (for front differential and AWD system).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Pvttemp Issues:
Overheating of the PVT system under heavy load or prolonged aggressive riding can lead to belt slippage or premature wear. Manual addresses proper belt tension and CVT cooling.
Suspension Wear:
Bushing and ball joint wear can occur with extensive use in rough conditions. Manual details inspection and replacement procedures.
Electrical Connector Corrosion:
Exposure to water and dirt can lead to corrosion of electrical connectors, causing intermittent issues. Manual includes diagnostic procedures for electrical gremlins.
Polarishistory:
Polaris Industries, founded in 1954, is a major American manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles. Known for innovation and rugged performance.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving over decades to incorporate technological advancements and diverse configurations, including the popular touring models.
500Cc Engine Significance:
The 500cc engine platform has been a long-standing workhorse for Polaris, recognized for its balance of power, reliability, and efficiency, making it a popular choice for utility and recreational use.
Manufacturing Location:
Primarily manufactured in the USA (Roseau, Minnesota and Spirit Lake, Iowa).
