Segment:
Mid-size utility ATV segment, known for versatility and recreational capability.
Competitors:
Competed with models from Honda (FourTrax), Yamaha (Grizzly), Suzuki (KingQuad), and Kawasaki (Bayou).
Features:
Independent front suspension, selectable 2WD/4WD, powerful engines for their class, and Polaris's signature automatic transmission (PVT).
Audience:
Recreational riders, hunters, farmers, and utility users seeking a capable and reliable ATV.
Covered Models:
Polaris Sportsman 400, Polaris Sportsman 500
Coverage Scope:
Complete tear down and rebuild, maintenance, troubleshooting, repair.
Estimated Pages:
Likely 300-500 pages based on typical factory service manuals for this era and vehicle type.
Type:
Factory Service Manual / Repair Manual
Engine:
Detailed specifications, disassembly, assembly, troubleshooting, tuning for both 400cc and 500cc variants.
Transmission:
CVT system (Primary and Secondary Clutch), gear case, drive system diagnostics and repair.
Drivetrain:
4WD system, front differential, rear differential, drive shafts, U-joints.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, bearings, alignment.
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake lines, bleeding procedures.
Electrical System:
Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), starter motor, battery, lighting.
Fuel System:
Carburetor(s) service and tuning, fuel pump, fuel lines, fuel tank.
Cooling System:
Radiator, fan, coolant, thermostat, water pump.
Frame And Body:
Chassis components, body panels, seat, handlebars, fenders.
Steering:
Steering mechanism, tie rods, ball joints, steering wheel.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, lubrication, brake adjustments.
Troubleshooting:
Systematic diagnostic procedures for common problems, fault finding charts.
Repair:
Step-by-step instructions for component repair and replacement.
Rebuild:
Complete engine and transmission rebuild procedures.
Diagnostics:
Electrical diagnostics, component testing, performance checks.
Assembly:
Detailed procedures for reassembling components after repair or overhaul.
Depth:
Comprehensive, suitable for both DIY enthusiasts and professional technicians. Covers from basic maintenance to complete engine rebuilds.
Visuals:
Includes pictures and part diagrams to illustrate procedures and component identification.
Model 400 Engine Type:
4-stroke, SOHC, 2-valve, single-cylinder
Model 400 Displacement:
375cc (approx.)
Model 500 Engine Type:
4-stroke, SOHC, 2-valve, single-cylinder
Model 500 Displacement:
499cc (approx.)
Model 400 Horsepower:
Approx. 24-26 HP (subject to variation)
Model 500 Horsepower:
Approx. 30-32 HP (subject to variation)
Fuel Delivery:
Carbureted (e.g., Mikuni BSR series common for this era)
Fuel Type:
Unleaded Gasoline (91+ octane recommended)
System:
CDI (Capacitor Discharge Ignition)
Type:
Polaris Variable Transmission (PVT) with engine braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch Type:
Automatic, belt-driven, centrifugal clutch system (primary and secondary)
Drive Modes:
2WD/4WD On-Demand
Specification:
Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 GL-5 gear oil for differential/transaxle components if separate)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 47 inches (119.4 cm)
Dry Weight:
Approx. 570-600 lbs (258-272 kg) depending on model variant
Towing Capacity:
Typically rated at 1500 lbs (680 kg)
Rack Capacity Front:
Typically rated at 90 lbs (41 kg)
Rack Capacity Rear:
Typically rated at 200 lbs (90 kg)
Safety Standards:
Manufactured to meet relevant ATV safety standards of the time; operator must wear appropriate safety gear.
Braking System:
Hydraulic disc brakes, front and rear.
Engine Braking:
Integrated into the PVT system for downhill control.
Frame Construction:
Steel frame designed for stability and durability.
Ergonomics:
Designed for rider control and comfort.
Features:
Basic dashboard indicators (speedometer, odometer, fuel gauge, 4WD indicator, engine warning light).
Features:
On-demand 4WD system, engine braking.
Features:
N/A (No advanced connectivity features typical for modern vehicles).
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Air Filter Cleaning:
Inspect every 50 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Check and gap every 50 hours; replace as needed (refer to manual for specific plug type and gap).
Transmission Oil Change:
Refer to manual, typically every 200 hours or 24 months for gearcase lubricant. CVT belt inspection at 50-100 hour intervals.
Engine Oil:
Polaris PS-4 10W-40 Synthetic or AMSOIL 4-Stroke Synthetic Motor Oil SAE 10W-40 (specific recommendations may vary, consult manual).
Coolant:
Ethylene glycol-based antifreeze (50/50 mix with distilled water recommended).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Cvtbelt:
Belt wear and potential slippage if not maintained or if overloaded. Regular inspection and replacement are crucial.
Carburetor:
Can be prone to clogging if fuel is not fresh or if air filtration is poor. Requires regular cleaning and adjustment.
Electrical Connections:
Corrosion or loose connections can lead to intermittent electrical issues. Keeping connections clean and sealed is important.
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.
Lineage:
The Sportsman line is one of Polaris's flagship ATV series, evolving through numerous iterations and engine sizes since its inception.
Manufacturing Location:
Primarily manufactured in the United States by Polaris.
Market Impact:
The Sportsman 400/500 models were highly popular and contributed significantly to Polaris's market share in the utility ATV segment.
