Segment:
Utility ATV, particularly suited for touring and demanding work applications (Forest Tractor designation).
Competitors:
Competes with other multi-purpose ATVs from manufacturers like Can-Am (Outlander), Yamaha (Grizzly), and Kawasaki (Brute Force).
Versatility:
Designed for both recreational touring and heavy-duty utility tasks, as indicated by the 'Forest Tractor' designation.
Touring Capability:
The 'Touring' model implies comfort and stability for longer rides, often with features like passenger seating.
Documentation Scope:
Comprehensive service, repair, maintenance, and troubleshooting for all listed models and years.
Estimated Pages:
Hundreds (specific count not provided in product info, but typical for full service manuals)
Type:
Service Repair Shop Manual
Device Compatibility:
PC, MAC, Tablets, Smartphones
Engine:
Detailed diagnostics, overhaul, tuning, fuel system, lubrication, cooling, ignition, exhaust.
Transmission:
Service, repair, and adjustments for automatic transmission (CVT), gearboxes, and driveline components.
Chassis And Frame:
Frame inspection, repair, suspension (front and rear), steering system, wheel alignment.
Brakes:
Hydraulic brake system diagnosis, caliper and master cylinder repair, brake fluid replacement, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator), starting system, lighting, instrumentation, ECM diagnostics.
Fuel System:
Fuel pump, fuel injectors (if applicable), carburetor (for some variants), fuel tank, lines, and filters.
Cooling System:
Radiator, fan, coolant, hoses, thermostat, water pump, overheat diagnosis.
Exhaust System:
Muffler, exhaust pipes, catalytic converter (if applicable), leak detection, repair.
Body And Trim:
Body panel removal/installation, seat removal, accessory mounting (e.g., cargo racks, winches).
Wheels And Tires:
Tire pressure, rotation, wheel bearing maintenance, rim specifications.
Preventative Maintenance:
Regular service checks, fluid changes, filter replacements, lubrication points.
Troubleshooting:
Diagnostic flowcharts, symptom-based repair guidance for common and uncommon issues.
Repair And Rebuild:
Step-by-step instructions for component disassembly, repair, and reassembly.
Adjustments:
Carburetor/fuel injection adjustments, throttle cable, brake adjustments.
Wiring Diagrams:
Detailed electrical schematics for accurate diagnosis and repair.
Special Tools:
Identification and usage of specific Polaris or aftermarket tools required for certain procedures.
Diagnostic Level:
Advanced diagnostics including error code interpretation, sensor testing, and ECM analysis.
Rebuild Capability:
Complete engine and transmission overhaul procedures with detailed specifications.
Specification Detail:
Torque values, clearances, fluid capacities, and electrical parameters.
Engine Type:
4-stroke, SOHC
Displacement 400:
375cc (for the 400 model variant)
Displacement 500:
499cc (for the 500 HO model variant)
Bore X Stroke 400:
Approx. 80mm x 75mm (typical for this displacement range)
Bore X Stroke 500:
Approx. 92mm x 75mm (typical for this displacement range)
Horsepower 400:
Estimated 25-30 HP (actual varies by year and tune)
Horsepower 500:
Estimated 34-38 HP (for HO model, actual varies)
Cooling System:
Liquid-cooled
Ignition System:
CDI (Capacitor Discharge Ignition)
Torque Characteristics:
Designed for strong low-end and mid-range torque for pulling and climbing.
Fuel Delivery 400:
Likely Carbureted (Mikuni or similar) for 2012-2013 400 model.
Fuel Delivery 500:
Likely Electronic Fuel Injection (EFI) for 500 HO model, for improved performance and cold starts.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Transmission Type:
Automatic Polaris Variable Transmission (PVT) with Engine Braking
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector.
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P).
Engine Braking:
Integrated engine braking for downhill control.
Final Drive:
Shaft drive (front and rear)
Length:
Approx. 83-85 inches (1.3-2.15m) (varies slightly between 400/500 and touring configurations)
Width:
Approx. 46-48 inches (1.17-1.22m)
Height:
Approx. 48-50 inches (1.22-1.27m)
Front Rack Capacity:
Typically 100 lbs (45 kg)
Rear Rack Capacity:
Typically 200 lbs (90 kg)
Dry Weight 400:
Approx. 600-650 lbs (272-295 kg)
Dry Weight 500:
Approx. 650-700 lbs (295-318 kg)
Towing Capacity:
Typically 1500 lbs (680 kg)
Gcvwr:
Gross Combined Vehicle Weight Rating specified in manual.
Atv Safety Standards:
Meets ANSI/ROHVA standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Engine Braking:
Provides additional control on descents.
On Demand AWD:
Enhances traction in challenging terrain.
Roll Over Protection:
Integral part of ATV design; manual covers safe operating practices.
Seat Belt Anchorage:
Not standard on most ATVs of this era; manual will emphasize proper helmet use and safety gear.
Oil Change:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for precise interval).
Air Filter Cleaning:
Recommended every 50 hours or as needed in dusty conditions.
Spark Plug Replacement:
Typically every 100 hours or annually.
Valve Lash Adjustment:
Often at 100-200 hour intervals, critical for engine performance.
Engine Oil Type:
Polaris Synthetic 2W-50 (or equivalent SAE 0W-40 / 10W-40 as per manual, check for specific grade).
Engine Oil Capacity:
Approx. 2 quarts (1.9 L) (refer to manual for exact capacity and filter type).
Transmission Fluid Type:
Polaris Premium ATV Lubricant or equivalent recommended fluid (e.g., SAE 75W-90 Gear Oil for some components, check manual).
Coolant Type:
Ethylene Glycol based antifreeze (e.g., Polaris Brand Antifreeze or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Drive belts, bushings, tie rod ends, ball joints are common wear items on ATVs due to heavy use.
Cv Joint Boots:
Can be susceptible to damage from debris; inspection and maintenance are crucial.
Cooling System Maintenance:
Regular flushing and filling of the cooling system prevents overheating issues.
