Polaris Sportsman 400 500 DUSE 2001 H.O. ATV Workshop Service Repair Manual

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Tipo: Atv

Proveedor:

SKU: 97137

Etiquetas: 2001 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500 DUSE

Variantes de producto

Descripción

This manual provides comprehensive service and repair information for the 2001 All-Terrain Vehicle (ATV). A respected American manufacturer, is known for its capable and comfortable off-road vehicles, and the line represents a significant part of its heritage. The 400 H.O. model, with its 375cc liquid-cooled, single-cylinder engine and Variable Transmission (PVT), is designed for recreational trail riding and utility tasks, offering a balance of power and reliability. This model features robust engineering, including a MacPherson strut front suspension and independent rear suspension for stability, along with a reliable shaft drive and on-demand all-wheel-drive system. This workshop service repair manual is your essential guide to maintaining and repairing your 2001 ATV. It covers a wide range of systems, including detailed procedures for the engine, fuel system, PVT transmission, drivetrain, suspension, braking, and electrical systems. You will find step-by-step instructions for maintenance tasks such as oil changes and filter replacements, as well as complex repair procedures for engine and transmission overhauls. Troubleshooting guides and detailed wiring diagrams are included to assist in diagnosing and resolving issues, ensuring your ATV remains in optimal working condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 H.O.

Sub Model:

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

Codes

Product Name:

Polaris Sportsman 400 500 DUSE 2001 H.O. ATV Workshop Service Repair Manual

👋 Introduction

Market Position

Market Segment:

Mid-range recreational and utility ATV, popular for trail riding and light work.

Competitive Analysis

Competitors:

Honda FourTrax, Yamaha Wolverine, Suzuki King Quad, Arctic Cat 400.

Key Features Vehicle

Key Features:

Polaris's long-standing reputation for capable 4x4 systems, comfortable ride, and powerful H.O. (High Output) engine.

Key Features Manual

Manual Value Proposition:

Provides essential knowledge for maintaining and repairing the 2001 Polaris Sportsman 400 H.O. DUSE, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for the specified model year and variants.

Page Count

Estimated Page Count:

300-500 (typical for this era's comprehensive manuals)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Engine disassembly, assembly, inspection, torque specifications, timing, lubrication, cooling system.

Fuel System:

Carburetor (likely Mikuni BSR42) overhaul, jetting, fuel pump, fuel lines, fuel tank maintenance.

Transmission System:

PVT (Polaris Variable Transmission) belt inspection, replacement, clutch service, gearcase maintenance, fluid changes.

Drivetrain System:

Driveshafts, U-joints, differential, all-wheel drive (AWD) engagement system (if applicable for DUSE variant), wheel bearings.

Suspension System:

Front and rear suspension components, shock absorbers, A-arms, bushings, wheel alignment.

Braking System:

Hydraulic brake system, calipers, master cylinders, brake lines, bleeding procedures, pad replacement.

Electrical System:

Ignition system, charging system (stator, voltage regulator), battery, lighting, starter motor, wiring diagrams, switch gear.

Steering System:

Handlebar assembly, steering post, tie rods, steering stem bearings.

Bodywork And Chassis:

Body panel removal and installation, frame inspection, seat, rack systems, graphics.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, coolant checks, valve adjustments.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common issues.

Repair Procedures:

Step-by-step disassembly and reassembly instructions for all major components.

Wiring Diagrams:

Detailed electrical system schematics for fault finding.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution scans for clear text and legible diagrams.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Features

Searchability:

Likely text-searchable PDF for quick access to information.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, Single Cylinder

Displacement:

375cc (for 400 H.O.)

Bore X Stroke:

Approx. 84.5 mm x 67 mm (typical for this engine family)

Cooling System:

Liquid-cooled

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approx. 28-30 HP (estimated for 400 H.O.)

Torque:

Not explicitly stated in product description, but typically around 25-30 lb-ft.

Fuel System

Carburetor Model:

Mikuni BSR42 (common for this model)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 3.2 US gallons (12.1 L)

🔧 Transmission

Standard

Transmission Type:

Polaris Variable Transmission (PVT)

Drive System:

Shaft Drive, On-Demand All-Wheel Drive (AWD)

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Clutch Type:

Centrifugal Clutch System

Gearcase Oil:

SAE 80W-90 Hypoid Gear Lubricant (refer to manual for specific Polaris spec)

📐 Dimensions

Exterior

Length:

Approx. 81 inches (2057 mm)

Width:

Approx. 46 inches (1168 mm)

Height:

Approx. 47 inches (1194 mm)

Wheelbase:

Approx. 50.5 inches (1283 mm)

Weights

Dry Weight:

Approx. 590 lbs (268 kg)

Ground Clearance:

Approx. 10.5 inches (267 mm)

Cargo

Front Rack Capacity:

Approx. 50 lbs (22.7 kg)

Rear Rack Capacity:

Approx. 100 lbs (45.4 kg)

Towing

Towing Capacity:

Approx. 1,225 lbs (556 kg)

🛡️ Safety Features

Ratings

Safety Certification:

ATV safety standards for its era.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

A Arm Design:

MacPherson strut front suspension, independent rear suspension (IRS) on some models, contributing to stability.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Operator Presence:

Handlebar control lockout for park/reverse.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic controls, no digital infotainment).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Engine Management

Ignition Control:

Basic CDI ignition system controlled by the ECU.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 1 year (whichever comes first).

Gearcase Oil Change:

Every 100 hours or 1 year.

Air Filter Service:

Clean every 25 hours or 1 month; replace as needed.

Spark Plug Replacement:

Inspect every 50 hours; replace as needed (refer to manual for specific plug type).

Pvt Belt Inspection:

Inspect every 50 hours; replace if worn or damaged.

Fluid Specifications

Engine Oil:

Polaris PS-4 Synthetic 0W-40 Engine Oil (or equivalent meeting API SG, JASO MA standards).

Coolant:

Ethylene glycol-based antifreeze/coolant for aluminum engines (50/50 mix with distilled water).

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Common Wear Items:

PVT belt wear, wheel bearings, steering stem bushings, exhaust system gaskets/leaks.

Carburetor Maintenance:

Carburetor jetting and cleaning can be crucial for optimal performance, especially with fuel variations.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, a long-standing American manufacturer of powersports vehicles.

Model Evolution

Sportsman Lineage:

The Sportsman line is known for its comfort, off-road capability, and often innovative features. The 2001 model is part of a generation that refined the Sportsman's design and performance.

Production

Production Years:

The 400 H.O. engine and Sportsman platform were produced for several years around this period, with iterative updates.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Polaris Sportsman models have consistently received positive reviews for their off-road performance and comfort within the ATV market.