Segment:
Mid-size utility ATV segment.
Target Audience:
Recreational riders, hunters, farmers, utility users seeking reliable and capable off-road transportation.
Key Competitors:
Can-Am Outlander, Honda Foreman, Yamaha Kodiak, Suzuki King Quad.
Positioning:
Polaris Sportsman line is known for its rider-friendly features, comfortable ride, and strong utility capabilities, often balancing performance with comfort and value.
Utility Focus:
Designed for work and play, with robust suspension and towing capacity.
User Friendliness:
Generally considered easy to operate and maintain, making it a popular choice for a wide range of riders.
Purpose:
Essential for owners and technicians to maintain, repair, and optimize the performance and longevity of the Polaris Sportsman 400/500.
Primary Coverage:
Complete workshop service and repair
Additional Coverage:
Maintenance, troubleshooting, diagnostics, technical specifications, diagrams, schematics
Estimated Pages:
Extensive (typical workshop manuals exceed 300 pages)
Type:
Workshop Service Repair Manual
Engine Systems:
Engine overhaul, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel system, ignition system, exhaust system
Drivetrain Systems:
Transmission, drive shafts, differentials, clutch, final drive
Electrical Systems:
Wiring diagrams, charging system, starting system, lighting, ignition, instrumentation, switches, sensors
Suspension Steering:
Front suspension, rear suspension, steering components, wheel alignment
Braking Systems:
Brake system components, hydraulic lines, calipers, rotors, parking brake
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor (if applicable), fuel injection system (if applicable)
Body Chassis:
Frame, body panels, fenders, racks, seat assembly
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, fluid checks, lubrication points
Repair Procedures:
Engine rebuilding, transmission overhauling, brake caliper replacement, suspension component repair, electrical diagnostics and repair
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common problem identification
Technical Data:
Torque specifications, clearances, tolerances, part numbers, fluid capacities, electrical resistance values
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Searchability:
Likely text-searchable, allowing for quick keyword lookup of procedures and parts.
Resolution:
High-resolution scans of original factory manuals, ensuring clarity of text and diagrams.
Scalability:
PDF format allows for zooming to view intricate details in diagrams and schematics.
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Engine Type 400:
4-stroke, SOHC, 2-valve, single-cylinder
Engine Displacement 400:
375cc
Engine Type 500:
4-stroke, SOHC, 2-valve, single-cylinder
Engine Displacement 500:
499cc
Bore X Stroke 400:
Approx. 83mm x 69mm (specifics in manual)
Bore X Stroke 500:
Approx. 93mm x 73.5mm (specifics in manual)
Cooling System:
Liquid-cooled
Horsepower 400:
Approx. 26-28 hp (varies by source)
Horsepower 500:
Approx. 34-36 hp (varies by source)
Torque 500:
Approx. 28-30 lb-ft (varies by source)
Fuel Delivery:
Carburetor (e.g., Mikuni BSR42 for 500 model)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type Engine:
SAE 0W-40 or 10W-40 Synthetic ATV/Motorcycle Oil (refer to manual for exact specification)
Oil Capacity Engine:
Approx. 1.7 US quarts (1.6 liters) (refer to manual for exact capacity)
Transmission Type:
Automatic (Polaris PVT™ - Continuously Variable Transmission)
Drive System:
Shaft drive, On-Demand All-Wheel Drive (AWD)
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch Type:
Centrifugal clutch
Belt Type:
Drive belt, secondary driven pulley (PVT)
Fluid Type Transmission:
Polaris specific transmission fluid or SAE 10W-30/10W-40 (refer to manual for exact specification and interval)
Fluid Capacity Transmission:
Approx. 0.5 US quarts (0.47 liters) (refer to manual for exact capacity)
Length:
Approx. 81 inches (2057 mm)
Width:
Approx. 46 inches (1168 mm)
Height:
Approx. 47 inches (1194 mm)
Wheelbase:
Approx. 50 inches (1270 mm)
Dry Weight:
Approx. 630 lbs (286 kg)
Ground Clearance:
Approx. 10.5 inches (267 mm)
Front Rack Capacity:
Approx. 100 lbs (45 kg)
Rear Rack Capacity:
Approx. 200 lbs (90 kg)
Towing Capacity:
Approx. 1,250 lbs (567 kg)
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheel Type:
Stamped steel
Fuel Capacity:
Approx. 3.2 US gallons (12.1 liters)
Atv Safety Standards:
Designed to meet ANSI/SVIA standards (for ATVs).
Braking System:
Hydraulic disc brakes front and rear.
A-Arm Suspension:
Independent front suspension for improved control and stability.
Operator Safety:
Handlebar controls, throttle limiter, footwells, seating position designed for rider control.
Lighting:
Dual halogen headlights, brake light.
Instrumentation:
Digital odometer, trip meter, hour meter, fuel gauge, gear indicator, AWD indicator, clock.
AWD System:
Polaris's proprietary On-Demand All-Wheel Drive system engages front wheels when rear wheels lose traction.
Accessory Integration:
Provisions for various Polaris accessories like winches, storage boxes, plow systems, and lighting upgrades.
Oil Change Interval:
Every 100 hours or 6 months (refer to manual for exact recommendation).
Air Filter Service:
Inspect every 20-40 hours, clean/replace as needed (more frequently in dusty conditions).
Spark Plug Service:
Replace every 100 hours or 1 year (refer to manual for specific spark plug type and gap).
Transmission Fluid Change:
Every 6 months or 100 hours (refer to manual for exact interval and procedure).
Drive Belt Inspection:
Inspect regularly for wear and damage, replace as needed (typically every 2 years or per manual recommendations).
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water (refer to manual for Polaris specific coolant).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual).
Pvf Belt Wear:
CVT belt wear is a common maintenance item across many ATVs. Regular inspection and timely replacement are crucial.
Carburetor Tuning:
Carburetors can require periodic cleaning and adjustment for optimal performance, especially with changes in altitude or fuel quality.
Suspension Bushings:
Wear on suspension bushings can lead to play and reduced handling; regular inspection is recommended.
Manufacturer:
Polaris Industries, founded in 1954, a pioneer in snowmobiles and later ATVs.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, versatility, and robust build since its introduction.
2001 2002 Updates:
These model years represent a period of refinement for the Sportsman platform, often featuring improvements in suspension, engine tuning, and accessory integration.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA.
