Segment:
Mid-size utility ATV segment, popular for trail riding, light work, and recreation.
Target Audience:
Owners and technicians performing maintenance, repair, and restoration of 2001 Polaris Sportsman 400 and 500 models.
Competitors:
Honda Foreman, Yamaha Kodiak, Arctic Cat 400/500, Suzuki TwinPeaks.
Differentiation:
Polaris Sportsman line known for its independent rear suspension (IRS) providing a smoother ride and better ground clearance compared to some competitors with solid rear axles in this era.
Independent Rear Suspension:
A significant feature for ride comfort and handling on rough terrain.
Comprehensiveness:
Provides factory-level detail for all major systems, enabling accurate diagnostics and repairs.
Visual Aids:
Includes pictures and part diagrams essential for accurate disassembly and reassembly.
Main Coverage:
Complete Service and Repair for 2001 Polaris Sportsman 400 & 500 ATVs
Specific Coverage:
Engine tear down and rebuild, drivetrain, suspension, brakes, electrical system, bodywork, troubleshooting, maintenance.
Estimated Page Count:
Likely 300-500+ pages (typical for comprehensive service manuals of this era and type, exact count not provided).
Type:
Official Service & Repair Manual
Powertrain:
Engine (disassembly, assembly, inspection, troubleshooting), transmission (PVT - Polaris Variable Transmission), final drive, drive shafts.
Chassis And Suspension:
Front and rear suspension systems, steering components, frame, A-arms, shocks, bushings.
Braking System:
Hydraulic brake system (calipers, master cylinders, lines), parking brake.
Electrical System:
Ignition system, lighting, battery, charging system (stator, voltage regulator), starter, wiring diagrams, diagnostic codes.
Bodywork And Accessories:
Body panels, fenders, racks, seat, controls, cooling system (radiator, fan).
Maintenance:
Regular service checks, oil changes, filter replacements, lubrication, valve adjustments, clutch service.
Repair And Rebuild:
Complete engine overhaul, transmission rebuild, suspension component replacement, electrical component diagnosis and repair.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, fault code interpretation.
Depth:
Comprehensive, covering everything from basic maintenance to full mechanical and electrical rebuilds, including torque specifications and detailed diagrams.
Searchability:
Likely text-searchable (standard for official PDF manuals).
Quality:
High-resolution, designed for clear viewing of text, diagrams, and photographs.
Binding:
N/A (Digital PDF download)
Paper Type:
N/A (Digital PDF download)
Engine Type:
4-stroke, SOHC, 2-valve, single-cylinder
Displacement:
375cc (approx.)
Bore X Stroke:
74.0 mm x 83.0 mm (example, requires manual verification)
Cooling System:
Liquid-cooled
Power Output:
Approx. 22-25 HP (estimated, specific dyno figures depend on exact tuning and model variation).
Engine Type:
4-stroke, SOHC, 2-valve, single-cylinder
Displacement:
499cc (approx.)
Bore X Stroke:
92.0 mm x 76.0 mm (example, requires manual verification)
Cooling System:
Liquid-cooled
Power Output:
Approx. 28-32 HP (estimated, specific dyno figures depend on exact tuning and model variation).
Carburetion:
Mikuni BSF34 carburetor (typical for both models, specific jetting may vary)
Fuel Type:
Unleaded gasoline, 87 octane (minimum recommended)
Type:
Polaris Variable Transmission (PVT) with Automatic Engine Braking (AEB)
Drive System:
Shaft drive, AWD (All-Wheel Drive) with On-Demand engagement
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch Type:
Primary and secondary clutch system (CVT)
Length:
Approx. 83 inches (210.8 cm) - Varies slightly between 400/500
Width:
Approx. 46 inches (116.8 cm) - Varies slightly between 400/500
Height:
Approx. 47 inches (119.4 cm) - Varies slightly between 400/500
Dry Weight:
Approx. 560-580 lbs (254-263 kg) - Varies between 400/500 and specific configurations
Ground Clearance:
Approx. 10.5 inches (26.7 cm)
Towing Capacity:
1500 lbs (680 kg) (typically)
Rack Capacity Front:
100 lbs (45 kg) (typically)
Rack Capacity Rear:
200 lbs (90 kg) (typically)
Atv Safety Standards:
Meets ANSI/SVIA 1-2001 safety standards for ATVs.
Automatic Engine Braking:
Provides engine braking downhill, enhancing control.
On Demand AWD:
Automatically engages front wheels when rear wheels lose traction, aiding in difficult terrain.
Handlebars:
Ergonomic design with hand guards (may be optional or standard depending on trim).
Seat:
Comfortable and secure seating position.
Operator Training:
Manual will emphasize the importance of reading the owner's manual and receiving proper ATV training before operation.
Display:
Basic LCD instrument cluster showing speed, odometer, trip meter, and gear indicator.
Engine Braking:
Automatic Engine Braking (AEB) system integrated into the PVT.
Charging System:
12V DC charging system with a stator to power lights and recharge the battery. Manual will cover charging system testing.
Oil Change Engine:
Every 100 hours or 1 year (whichever comes first). Manual will specify exact interval and procedure.
Air Filter Cleaning:
As needed, typically every 20-40 hours depending on operating conditions. Manual will detail inspection and cleaning/replacement.
Spark Plug Replacement:
Refer to manual, often around 100-200 hours or as per inspection.
Belt Inspection Pv T:
Inspect every 50 hours, replace as needed. Manual provides specific wear limits.
Engine Oil:
Polaris Synthetic 2W-50 PS-4 or equivalent API SG/SH rated oil. Manual will specify exact API rating and viscosity.
Engine Oil Capacity:
Approx. 2.0 US quarts (1.9 L) (Requires manual verification).
Gearcase Oil:
Polaris Synthetic Gearcase Lubricant (75W-140). Manual will specify exact type and API rating.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Manual will specify exact type.
Pv T Belt Wear:
CVT belt wear and potential slippage is a common maintenance item on many ATVs, including these models. Proper belt tension and condition are critical.
Cooling System Maintenance:
Ensuring the radiator and fan are clean and functioning is vital for preventing overheating, especially under heavy load or in warm conditions.
Suspension Bushings:
Wear on A-arm and suspension bushings can lead to play in steering and uneven tire wear over time.
Manufacturer:
Polaris Industries Inc. is a long-standing American manufacturer known for its pioneering work in snowmobiles and ATVs.
Sportsman Line:
The Sportsman line, introduced in the early 1990s, evolved into a benchmark for utility and recreational ATVs, with the 400 and 500 models being core offerings for many years.
Manufacturing Location:
Polaris ATVs are typically manufactured in the United States.
Year Significance:
2001 models represent a mature iteration of the Sportsman platform, incorporating features refined from previous years.
Industry Acclaim:
While specific awards for the 2001 model year are not provided, the Polaris Sportsman line consistently received positive reviews for its performance, comfort, and utility during this era.
Customer Satisfaction:
Generally high for its class, reflecting its robust design and capability.
Regulatory Compliance:
Meets relevant safety and emissions standards for its production year and market.
