Target User:
Recreational riders, farmers, hunters, and light utility work.
Competitors:
Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou/Prairie, Suzuki King Quad during the specified model years.
Powertrain:
Robust single-cylinder engines, reliable automatic CVT transmissions, selectable 2WD/AWD.
Design:
Comfortable rider ergonomics, independent front suspension, MacPherson strut front suspension, swingarm rear suspension.
Value:
Provides essential, accurate, and detailed information crucial for maintaining and repairing these durable ATVs, saving significant costs compared to dealership service.
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor tuning, fuel pump), exhaust system.
Transmission:
CVT (Continuously Variable Transmission) system, clutch removal/installation, belt inspection/replacement, gearcase service, fluid changes.
Drivetrain:
Front and rear drive systems, differential service, driveshafts, U-joints, axle repair, AWD system troubleshooting.
Suspension Steering:
Front and rear suspension components, shock absorber service, ball joints, bushings, steering linkage, tie rod ends, wheel bearings.
Brakes:
Hydraulic brake system, caliper service, brake pad replacement, master cylinder, brake lines, bleeding procedures, parking brake.
Electrical:
Wiring diagrams, ignition system, starting system, charging system (stator, regulator/rectifier), battery maintenance, lighting, switches, fuses, troubleshooting electrical faults.
Fuel System:
Fuel tank, fuel lines, fuel pump, carburetor (Mikuni VM series typically), fuel filter, troubleshooting fuel delivery issues.
Cooling System:
Radiator, cooling fan, hoses, thermostat, coolant specifications and flushing procedures.
Body Frame:
Body panels, fenders, racks, seat removal, frame inspection, plastics repair.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments, spark plug replacement, battery care.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault codes (if applicable).
Repair Rebuild:
Step-by-step instructions for component disassembly, repair, and reassembly of all major systems.
Inspection:
Pre-ride inspections, detailed component inspection guidelines for wear and damage.
Tune Up:
Carburetor adjustment, ignition timing checks, idle speed settings.
Depth:
Comprehensive, covering everything from basic preventative maintenance and fluid checks to complete engine rebuilds, transmission overhauls, and complex electrical system diagnostics.
Target Audience:
Professional technicians, experienced DIY mechanics, and owners who want detailed, accurate repair information.
Sportsman 400 Engine:
400cc, 4-stroke, liquid-cooled, SOHC, single-cylinder engine (specific bore/stroke varies by exact sub-model within the 400 range).
Sportsman 500 Engine:
499cc, 4-stroke, liquid-cooled, SOHC, single-cylinder engine (e.g., 92mm bore x 75mm stroke).
Xplorer 500 Engine:
499cc, 4-stroke, liquid-cooled, SOHC, single-cylinder engine (similar to Sportsman 500).
Horsepower Range:
Approximately 25-32 HP depending on engine size and year.
Torque Specifications:
Torque curves and specific values for each engine variant will be detailed in the manual.
Carburetor Type:
Typically Mikuni VM30SS or similar single-barrel carburetor for most models, with specific jetting and adjustment procedures detailed.
Fuel Requirement:
Unleaded gasoline, 87 octane (minimum recommended).
Oil Type:
SAE 10W-40 API SG or higher, specifically formulated for wet clutches (e.g., JASO MA).
Oil Capacity:
Approximately 2.0-2.5 liters (including filter) depending on the specific model and engine.
Coolant Type:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Coolant Capacity:
Approximately 1.5-2.0 liters.
Type:
Automatic, belt-driven Continuously Variable Transmission (CVT) with High/Low range and Reverse.
Gear Ratios:
Specific gear ratios for High, Low, and Reverse ranges detailed in the manual.
Clutch System:
Primary drive clutch (inboard) and secondary driven clutch (outboard) with detailed inspection and service procedures.
Gearcase Oil Type:
SAE 80W-90 GL-4 gear oil.
Gearcase Oil Capacity:
Approximately 0.25-0.35 liters for the rear gearcase.
Length Approx:
Typically around 80-85 inches (2032-2159 mm).
Width Approx:
Typically around 46-48 inches (1168-1219 mm).
Height Approx:
Typically around 46-48 inches (1168-1219 mm).
Dry Weight Approx:
Approximately 550-650 lbs (250-295 kg).
Payload Capacity:
Front rack: ~100 lbs (45 kg), Rear rack: ~200 lbs (90 kg).
Towing Capacity:
Typically 1,500 lbs (680 kg).
Front Tire Size Std:
25x8-12 or 25x8x12.
Rear Tire Size Std:
25x10-12 or 25x10x12.
Wheel Bolt Pattern:
4x110mm (common for this era).
Engine Oil Change:
Every 100 hours or annually, whichever comes first. Check manual for specific conditions.
Air Filter Cleaning:
Check every 25 hours, clean or replace as needed, especially in dusty conditions. Manual provides cleaning procedures.
Spark Plug Replacement:
Recommended every 100 hours or annually. Manual will specify gap and type (e.g., NGK CR7HSA or similar).
Cv Belt Inspection:
Inspect every 50 hours for wear, cracks, and proper tension. Replace as needed.
Valve Adjustment:
Check clearance every 100 hours or annually. Manual provides specific clearances and adjustment procedures.
Engine Oil Spec:
SAE 10W-40 API SG or higher, JASO MA compliant.
Gearcase Oil Spec:
SAE 80W-90 GL-4.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Spec:
50/50 mix of ethylene glycol antifreeze and distilled water.
Common Wear Items:
CVT belts, ball joints, tie rod ends, wheel bearings, brake pads, spark plugs, starter solenoid.
Potential Electrical:
Voltage regulator/rectifier failure, stator issues, starter motor contactor problems can occur with age.
Carburetor Issues:
Clogged jets, float bowl issues, and diaphragm wear are common if fuel is left stagnant or contaminated.
Suspension Wear:
Bushings in A-arms and control arms can wear out, leading to play and steering issues.
Polarissportsman Line:
The Polaris Sportsman line is renowned for its utility and comfort, established as a leading ATV platform in the 1990s.
Evolution Sportsman 500:
The Sportsman 500, introduced in 1996, quickly became a benchmark for the industry, offering a balance of power, comfort, and capability, evolving through various iterations including EFI and independent rear suspension (IRS) in later models.
Evolution Sportsman 400:
The Sportsman 400 served as a more budget-friendly option, offering a capable package for riders who didn't need the full power of the 500, often featuring a MacPherson strut front suspension.
Evolution Xplorer 500:
The Xplorer line was positioned more towards sport-touring and utility, sharing many components with the Sportsman series.
Manufacturing Location:
Primarily manufactured by Polaris Industries in Roseau, Minnesota, USA.
Key Innovations Era:
This period saw Polaris solidify its market leadership with reliable powertrains and user-friendly designs.
