Category:
Premium Utility/Recreational ATV
Target Audience:
Off-road enthusiasts, hunters, farmers, and recreational riders seeking a capable and comfortable two-up ATV.
Key Competitors 2008:
Can-Am Outlander 800, Yamaha Grizzly 700, Arctic Cat Thundercat 1000, Kawasaki Brute Force 750.
Touring Capability:
Designed for two-up riding with a comfortable seat and passenger footrests.
Engine Type:
Fuel-injected, liquid-cooled, single-cylinder engine for reliable performance.
Suspension Type:
Independent front and rear suspension for superior ride comfort and handling.
Drivetrain Features:
Switchable on-demand AWD system for optimal traction in various conditions.
Engine:
Complete engine overhaul, diagnosis, and repair, including top-end and bottom-end components, lubrication system, cooling system, and timing.
Fuel System:
EFI system diagnosis and repair, fuel pump, injectors, pressure regulator, throttle body, and sensors.
Drivetrain:
All-wheel drive (AWD) system, viscous differential, rear differential, drive shafts, CV joints, and clutches (primary and secondary).
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) inspection, maintenance, and repair, belt replacement, sheave inspection.
Brakes:
Hydraulic braking system, calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, ball joints, tie rods, and wheel bearings.
Steering:
Steering system diagnosis and repair, steering shaft, tie rods, steering column, and any associated components.
Electrical:
Complete electrical system, battery, charging system (stator, voltage regulator), ignition system, lighting, starter motor, and wiring diagrams.
Body Frame:
Body panel removal and installation, chassis inspection and repair, seat, handlebars, and rack components.
Maintenance:
Regular maintenance procedures, including oil changes, filter replacements, spark plug service, lubrication points, and valve adjustments.
Troubleshooting:
Diagnostic charts and troubleshooting guides for common issues and symptoms, aiding in problem identification.
Repair:
Step-by-step repair instructions for all major vehicle components and systems.
Assembly Disassembly:
Detailed instructions for the disassembly and reassembly of all major mechanical and electrical parts.
Diagnostic Capabilities:
Advanced diagnostic procedures, including understanding EFI codes and sensor outputs.
Rebuild Procedures:
Comprehensive rebuild procedures for major components such as the engine and transmission.
Specifications:
Detailed torque specifications, clearances, and tolerances for all adjustable and replaceable parts.
Wiring Diagrams:
Complete, easy-to-read electrical wiring diagrams for all vehicle systems.
Engine Type:
4-stroke, SOHC, 4-valve
Bore X Stroke:
92mm x 75mm
Cooling System:
Liquid-cooled
Horsepower Est:
Approx. 39 HP @ 6500 RPM (Note: Official Polaris figures may vary slightly)
Torque Est:
Approx. 35 lb-ft @ 5000 RPM (Note: Official Polaris figures may vary slightly)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Ignition Type:
Electronic ignition
Oil Type:
SAE 5W-50 Synthetic Oil (Refer to manual for specific Polaris recommendations)
Oil Capacity:
Approx. 2.1 L (2.2 U.S. qt)
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft drive, On-Demand AWD
Clutch Type:
Dual clutch (Primary and Secondary)
Transmission Fluid:
Polaris Synthetic AWD/Transmission Fluid (Refer to manual for specific part number and type)
Atv Safety Standards:
Manufactured to meet ANSI standards for off-highway utility vehicles. Operator training and safety gear are essential.
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
PVT system provides inherent engine braking in lower gears.
Aawd System:
On-demand AWD automatically engages front wheels when rear wheels lose traction.
Seatbelts:
N/A (ATVs typically use operator restraints, not seatbelts).
Roll Over Protection:
N/A (ATVs are open-cockpit vehicles; proper riding technique and safety gear are paramount).
Hand Guards:
Integrated handguards for protection from trail debris.
Display Features:
Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, AWD status, and indicator lights.
Aawd System:
Automatic All-Wheel Drive (AWD) system for enhanced traction and control.
Lighting:
Dual 50W headlights, dual 30W tail/brake lights.
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Transmission Fluid Change:
Every 200 hours or 24 months.
Air Filter Cleaning:
Clean every 25 hours; replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement:
Inspect every 100 hours; replace as needed. (Refer to manual for specific part number and gap).
Belt Inspection:
Inspect primary and secondary drive belts every 50 hours for wear and damage.
Engine Oil:
Polaris PS-4 5W-50 Synthetic Engine Oil or equivalent SAE 5W-50 synthetic oil.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Cooling System Coolant:
50/50 mix of Polaris Premium Antifreeze/Coolant and distilled water (or equivalent ethylene glycol-based coolant rated for -34°F).
Drive Belt Wear:
Drive belts can wear prematurely if subjected to excessive slippage, heat, or improper alignment. Regular inspection is key.
Efi Sensor Issues:
Sensors like the throttle position sensor (TPS) or crank position sensor can sometimes fail, affecting engine performance. The manual details diagnostic procedures.
Suspension Bushings:
Over time, suspension bushings can wear out, leading to play and noise. The manual covers inspection and replacement.
Polaris Heritage:
Polaris Industries is a long-standing American manufacturer of powersports vehicles, known for innovation and off-road capabilities since its founding in 1954.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving through numerous iterations to incorporate advanced features like EFI and independent suspension.
Touring Variant:
The 'Touring' designation signifies a model specifically designed with enhanced comfort and passenger capacity for extended rides.
Model Year Introduction:
The Sportsman 500 model line has been in production for many years, with the Touring EFI variant gaining popularity in the mid-2000s.
