Primary Coverage:
Complete Service, Repair, Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams, Specifications, Exploded Views
Specific Components:
Engine, Transmission, Drivetrain, Suspension, Brakes, Steering, Electrical System, Fuel System, Cooling System, Chassis, Bodywork, Accessories
Estimated Pages:
Extensive (typical for complete workshop manuals covering multiple years and models; exact page count not specified in product description but expected to be several hundred)
Type:
Workshop Service Repair Manual
Engine Mechanical:
Engine assembly, disassembly, inspection, internal component specifications, piston rings, crankshaft, camshaft, valve train, cylinder head, block, oil pump, timing system.
Fuel System:
Carburetor (or EFI system if applicable), fuel pump, fuel filter, fuel lines, tank, venting system, emissions control.
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, coolant specifications, bleeding procedures.
Ignition System:
Ignition coil, spark plugs, CDI unit, stator, ignition timing, troubleshooting.
Drivetrain:
All-Wheel Drive (AWD) system, 2WD/4WD engagement, differential systems (front and rear), axle shafts, CV joints, drive shafts.
Transmission Drivetrain:
Automatic Transmission (PVT - Polaris Variable Transmission), clutch system (drive clutch, driven clutch), belt inspection and replacement, gear case lubrication, shifting mechanisms.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, control arms, alignment specifications, adjustment procedures.
Steering:
Handlebar assembly, steering linkage, tie rods, steering column, steering stops, troubleshooting steering play or binding.
Braking System:
Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake discs, parking brake, bleeding procedures, fluid specifications.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, wiring diagrams, fuse box, diagnostic connectors.
Chassis Frame:
Frame inspection, welds, mounts, protective components, skid plates, hitch systems.
Bodywork Plastics:
Body panels, fenders, racks, seat assembly, dashboard, removal and installation procedures.
Basic Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable), spark plug replacement, air filter cleaning/replacement, tire pressure checks, lubrication points.
Routine Service:
Scheduled maintenance checks, belt inspection, brake fluid flush, coolant flush, valve clearance adjustment (if applicable).
Engine Repair:
Complete engine rebuilds, piston and ring replacement, crankshaft and connecting rod repair, cylinder head gasket replacement, timing chain/belt service.
Transmission Service:
PVT belt replacement, clutch service, transmission oil change, gear case rebuilds (if applicable).
Drivetrain Repair:
CV joint boot replacement, axle shaft replacement, differential service, AWD system troubleshooting.
Suspension And Steering Repair:
Shock absorber replacement, bushing replacement, wheel bearing replacement, tie rod end replacement, steering system adjustment.
Brake System Overhaul:
Brake pad replacement, caliper rebuild, master cylinder replacement, brake line replacement, bleeding the hydraulic system.
Electrical Diagnostics:
Troubleshooting starting issues, charging system problems, lighting faults, using wiring diagrams to trace circuits.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting tables.
Wiring Diagrams:
Detailed electrical schematics for all systems, including color coding and component identification.
Depth:
Comprehensive: Covers everything from basic preventive maintenance and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Suitable for both DIY enthusiasts and professional technicians.
Engine Type:
4-Stroke Single Cylinder (likely SOHC or OHC)
Engine Displacement:
400cc and 500cc HO (High Output) variants.
Bore X Stroke:
Specifications vary by exact engine displacement, but typical for this class. Manual will contain precise measurements.
Cooling System:
Liquid-Cooled
Engine Oil Type:
Polaris PS-4 4-stroke synthetic oil (typically SAE 0W-40 or 10W-40, refer to manual for specific viscosity and API service classification)
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter. Manual will confirm exact capacity.
Spark Plug Type:
NGK CR7HSA or equivalent (verify with manual)
Horsepower:
Approx. 27-30 HP for 400cc, Approx. 32-35 HP for 500 HO (estimated, exact figures in manual)
Torque:
Specifications not readily available, but designed for low-end torque for utility. Manual will provide torque figures for engine components.
Fuel Delivery:
Carburetor (likely Keihin or Mikuni for this era) or Throttle Body Fuel Injection (EFI) for some variants. Manual specifies exact system.
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Length:
Approx. 85.1 inches (2161 mm) for Touring models (verify specific model variant in manual).
Width:
Approx. 46 inches (1168 mm) (verify specific model variant in manual).
Height:
Approx. 49.6 inches (1260 mm) (verify specific model variant in manual).
Wheelbase:
Approx. 57 inches (1448 mm) for Touring models (verify specific model variant in manual).
Front Rack Capacity:
Approx. 100 lbs (45 kg) (verify specific model variant in manual).
Rear Rack Capacity:
Approx. 200 lbs (90 kg) (verify specific model variant in manual).
Dry Weight:
Approx. 660 lbs (299 kg) for standard models, Touring heavier. Manual will provide exact specifications.
Towing Capacity:
1500 lbs (680 kg) (verify specific model variant in manual).
Payload Capacity:
Approx. 465 lbs (211 kg) (verify specific model variant in manual).
Front Tire Size:
25 x 8-12 (verify specific model variant in manual).
Rear Tire Size:
25 x 10-12 (verify specific model variant in manual).
Wheel Bolt Pattern:
4x110mm (verify in manual)
First Service:
Typically around 10-20 operating hours or 1 month for initial break-in service (oil change, filter check, lubrication). Detailed schedule in manual.
Regular Oil Change:
Every 100 operating hours or 6 months, whichever comes first (verify specific interval in manual).
Air Filter Cleaning:
Every 50 operating hours or as needed based on conditions (more frequent in dusty environments). Manual specifies cleaning/replacement intervals.
Transmission Oil Change:
Every 100 operating hours or annually (verify specific interval in manual).
Belt Inspection:
Every 50 operating hours or annually (verify specific interval in manual). Replacement recommended based on wear and tear.
Engine Oil:
Polaris PS-4 4-stroke synthetic oil (SAE 0W-40 or 10W-40, API SJ or higher). Refer to manual for precise recommendation.
Gearcase Oil:
Polaris Synthetic Gearcase Lubricant (specific viscosity and part number in manual).
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Polaris recommends specific coolant. Manual will list part number and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies exact type.
Common Wear Items:
PVT belt wear, suspension bushings, wheel bearings, tie rod ends, brake pads, and starter motor reliability can be common wear items on ATVs with heavy use.
Electrical Connections:
Corrosion on electrical connectors can sometimes lead to intermittent issues; proper maintenance and dielectric grease application are key.
Cooling System Maintenance:
Ensuring proper coolant levels and condition is crucial to prevent overheating, especially under heavy load.
