Vehicle Segment:
Utility ATV, suitable for work, hunting, and recreational trail riding
Target Audience:
ATV owners seeking to perform their own maintenance and repairs
Competitors:
Yamaha Grizzly, Honda Foreman, Kawasaki Brute Force
Vehicle Strength:
Robust build, reliable engine options, excellent suspension for its class
Manual Value Proposition:
Comprehensive coverage for DIY repairs, saving on dealership service costs
Coverage Scope:
All Models and Repairs A-Z
Repair Types Covered:
Mechanical and Electrical Repairs
Estimated Page Count:
Not explicitly stated, but described as comprehensive
Type:
Workshop Service Repair Manual
Download Format:
PDF Download
Engine System:
Complete engine overhaul, diagnostics, tuning, and component repair
Fuel System:
Carburetor servicing, fuel pump, fuel lines, tank maintenance
Cooling System:
Radiator, fan, thermostat, coolant flushing and replacement
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting, ignition system, ECU diagnostics
Transmission System:
PVT (Polaris Variable Transmission) servicing, belt replacement, gearcase maintenance
Drivetrain System:
Front and rear drive shafts, differentials, CV joints, hub assembly service
Suspension System:
Front and rear shock absorbers, A-arms, bushings, wheel bearings
Braking System:
Hydraulic brake system, caliper servicing, brake pad replacement, bleeding procedures
Steering System:
Handlebar assembly, tie rods, steering post, universal joints
Chassis Frame:
Frame inspection, straightening, component mounting
Bodywork Plastics:
Fender removal, panel repair and replacement
Routine Maintenance:
Oil changes, filter replacements, lubrication points, air filter cleaning/replacement
Troubleshooting:
Diagnostic charts, symptom analysis, common problem identification
Repair Procedures:
Step-by-step instructions for all mechanical and electrical components
Rebuild Procedures:
Complete engine and transmission rebuild guidance
Adjustment Procedures:
Valve adjustments, carburetor synchronization, clutch engagement settings
Depth:
Comprehensive, from basic maintenance to complete overhaul and diagnostics
Visual Aid Quality:
Tons of detailed pictures and diagrams included
Diagnostic Focus:
Detailed diagnostic procedures for electrical and mechanical issues
Engine Displacement 400:
376cc (for Sportsman 400 models)
Engine Displacement 500:
499cc (for Sportsman 500 models)
Engine Configuration:
Single-cylinder, SOHC
Cooling Method:
Liquid-cooled
Bore X Stroke 400:
Approx. 82mm x 71.2mm (verify with manual)
Bore X Stroke 500:
Approx. 92mm x 92mm (verify with manual)
Compression Ratio 400:
Approx. 9.7:1 (verify with manual)
Compression Ratio 500:
Approx. 8.5:1 (verify with manual)
Horsepower Estimate:
Estimated 25-35 HP (varies by specific model variant)
Torque Estimate:
Estimated 25-35 lb-ft (varies by specific model variant)
Fuel Delivery:
Carburetor (e.g., Mikuni BSR42/44)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Type:
Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:
Automatic, High/Low Range, Reverse, Neutral, Park
Clutch System:
Automatic Centrifugal Clutch, Drive and Driven Sheaves
Drive System:
Shaft Drive, AWD/2WD On-Demand
Atv Safety Standards:
Complies with ANSI/SVIA 1-2001 and 2-2001 standards
Braking Type:
Hydraulic disc brakes, front and rear
Drive Mode Selection:
On-Demand All-Wheel Drive (AWD)
Lighting:
Dual Halogen headlights, incandescent tail/brake light
Infotainment System:
Basic analog/digital instrument cluster (speedometer, odometer, trip meter, fuel gauge, warning lights)
Transmission Feature:
Engine braking from PVT system
Drive Mode Selection Feature:
On-Demand AWD engagement
Connectivity Features:
N/A (No Bluetooth, USB, or smartphone integration on this model)
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first)
Gearcase Oil Change:
Every 200 hours or 1 year
Spark Plug Replacement:
Recommended every 100 hours or annually
Air Filter Cleaning:
Check every 20 hours, clean as needed; replace every 200 hours or if damaged
Drive Belt Inspection:
Inspect every 50 hours for wear and damage; replace if necessary (typically between 1000-2000 miles or sooner based on condition)
Engine Oil Type:
SAE 5W-50 Synthetic or Polaris PS-4 Premium 4-Stroke Engine Oil
Engine Oil Capacity:
Approx. 1.7 quarts (1.6 liters) (verify with manual)
Gearcase Oil Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 75W-90
Gearcase Oil Capacity:
Approx. 9 oz (266 ml) (verify with manual)
Coolant Type:
Ethylene Glycol based, minimum 50% antifreeze/50% distilled water mix
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Problem 1:
PVT Belt Wear: Frequent belt replacement due to heat and load
Common Problem 2:
Water Pump Seal Leaks: Potential for coolant leaks at the water pump
Common Problem 3:
Electrical Connector Corrosion: In wet environments, connectors can corrode affecting systems
Common Problem 4:
Carburetor Jetting: May require adjustment based on altitude and modifications
Manufacturer:
Polaris Industries, Inc.
Founding:
Founded in 1954, known for snowmobiles before ATVs
Sportsman Line Introduction:
Polaris introduced its first ATVs in the late 1980s, with the Sportsman line becoming a flagship model
2005 Updates:
The 2005 models often featured refinements to the PVT, engine tuning, and suspension compared to earlier generations
Manufacturing Location:
Typically manufactured in the USA by Polaris Industries
