Market Segment:
Polaris's Sportsman line is a dominant force in the utility and recreational ATV market, known for its durability, performance, and versatility. The Touring model specifically targets riders who value comfort and capability for longer excursions.
Competitors:
Competes with models from Yamaha (Grizzly), Can-Am (Outlander), Arctic Cat (Prowler), Kawasaki (Brute Force), and Honda (Foreman/Rubicon) in the 500cc+ utility/touring ATV segment.
Touring Focus:
Extended wheelbase for improved stability and passenger comfort, comfortable seating for two, higher ground clearance, robust suspension system for varied terrain.
Target Audience:
Primarily mechanical technicians, but also valuable for experienced ATV owners undertaking their own maintenance and repairs.
Engine:
Complete engine overhaul, internal components, cooling system, lubrication system, fuel delivery, ignition system
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), drive clutches, driven clutches, belt replacement, gearbox, drive shafts, differentials, CV joints, AWD system (if applicable)
Suspension Steering:
Front and rear suspension (independent front suspension, dual trailing arm rear suspension), shock absorbers, springs, bushings, steering system, tie rods, steering column
Brakes:
Hydraulic disc brakes (front and rear), brake caliper service, master cylinder, brake lines, bleeding procedures
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, ignition switch, lights, instrumentation, sensors, ECUs
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor (likely Keihin or Mikuni for this model), fuel lines
Bodywork Frame:
Frame inspection, body panels, fenders, racks, seat, handlebars, plastics
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, coolant type and capacity
Maintenance:
Scheduled maintenance (oil changes, filter replacements, spark plugs, valve adjustments), lubrication points, inspection routines
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common issues, electrical system fault finding
Repair Rebuild:
Step-by-step instructions for component disassembly, repair, and reassembly (e.g., engine rebuild, transmission service, brake caliper overhaul)
Technical Specifications:
Torque specifications, clearances, measurements, fluid capacities, electrical resistance values
Component Identification:
Identification of key parts and components with diagrams
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics; covers from basic maintenance to major overhauls and diagnostics
File Format:
PDF (Portable Document Format)
Print Quality:
High-resolution, optimized for digital viewing and printing, clear diagrams and text
Binding Type:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Searchable Text:
Typically searchable text within the PDF for quick information retrieval
Illustrations Included:
Detailed diagrams, exploded views, schematics, and photographic illustrations
Engine Type:
4-stroke, SOHC (Single Overhead Cam), 4-valve, liquid-cooled
Engine Displacement:
499cc
Bore X Stroke:
92.0 mm x 75.0 mm
Horsepower Est:
Approx. 30-35 HP (at flywheel, manufacturer specific)
Torque Est:
Approx. 30-35 lb-ft (at flywheel, manufacturer specific)
Fuel Induction:
Carburetor (likely Mikuni BSR42 or similar)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Cooling Method:
Liquid-cooled with fan assist
Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil
Oil Capacity W Filter:
Approx. 2.2 L (74 fl oz)
Transmission Type:
Automatic, Polaris Variable Transmission (PVT)
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD)
Clutch System:
Primary (Drive) Clutch and Secondary (Driven) Clutch
Gear Reduction:
Integral gearbox with reduction ratios provided in manual
Transmission Fluid Type:
Polaris PVT fluid or equivalent (check manual for specific P/N)
Safety Standards:
Manufactured to meet EPA and state requirements; compliance with ANSI/SVIA standards may be indicated.
Braking System:
Hydraulic disc brakes front and rear, engine braking through PVT system.
AWD System:
On-Demand AWD for enhanced traction in challenging conditions.
Lighting:
Dual headlights, brake light/taillight.
Ergonomics:
Comfortable seating for two, ergonomic handlebar setup.
Instrument Cluster:
Digital odometer, trip meter, speedometer, engine hour meter, clock, fuel gauge, AWD indicator, gear position indicator.
Braking Aid:
Engine braking provided by the PVT system.
Diagnostic Ports:
On-board diagnostic capabilities; the manual will detail diagnostic codes and procedures.
Engine Oil Change:
Every 100 hours or annually (whichever comes first)
Air Filter Cleaning Replacement:
Inspect every 50 hours, clean or replace as needed; more frequently in dusty conditions.
Spark Plug Replacement:
Every 100 hours or annually
Clutch Belt Inspection Replacement:
Inspect every 100 hours for wear and damage; replace as needed. Belt life varies greatly with usage.
Valve Clearance Adjustment:
Every 200 hours or annually
Engine Oil:
SAE 10W-40, API SG/SH/SJ/SL/SM, JASO MA
Transmission Fluid:
Polaris PVT Fluid (P/N 2871198 or equivalent)
Coolant:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Capacity approx. 1.5 L (50 oz).
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Common Wear Items:
Drive belt, wheel bearings, tie rod ends, ball joints, suspension bushings.
Potential Engine Problems:
Cam chain tensioner wear, oil leaks, carburetor tuning issues, starter solenoid failures.
Electrical Quirks:
Wiring harness chafing, corrosion in electrical connectors, stator or regulator/rectifier failure.
Drive Clutch Rebuild:
Regular maintenance and cleaning of drive clutch components can prevent premature wear.
Cv Boot Replacement:
Frequent inspection of CV boots for tears is crucial to prevent joint damage.
Brand Established:
Polaris Industries Inc. was founded in 1954, with a strong history in snowmobiles and later expanding into ATVs, UTVs, and motorcycles.
Sportsman Line Inception:
The Polaris Sportsman line debuted in 1993 and quickly became a market leader, known for its innovation and capability.
Touring Variant:
The 'Touring' designation was introduced to offer a more comfortable, longer-distance riding experience, often featuring a longer chassis and two-up seating.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States, with significant operations in Roseau, Minnesota and Spirit Lake, Iowa.
Model Year Range:
The Sportsman 500 platform has been in production for many years, with the Touring variant seeing updates and refinements throughout its lifecycle.
