Target Audience:
Polaris ATV owners and independent repair shops seeking professional-grade service information.
Value Proposition:
Provides the same level of detail and accuracy as official dealer manuals, enabling DIY repairs and informed maintenance, saving costs compared to dealership service.
Content Highlights:
Step-by-step instructions, clear pictures, exploded view illustrations, schematics, specifications, troubleshooting guides.
Replacement Policy:
Free replacement offered if the manual is lost.
Vehicle Model Years:
Sportsman 400 (2001-2003), Sportsman 500 (1996-2003), Worker 500 (1997-2001), Xplorer 500 (1997)
Estimated Page Count:
Exact page count not specified, but typical dealer service manuals of this era are extensive, often exceeding 500 pages for comprehensive coverage.
Type:
Dealership Service Manual / Repair Manual
Powertrain:
Engine overhaul, fuel system, ignition system, exhaust system, transmission (PVT - Polaris Variable Transmission), drive shafts, differentials.
Chassis And Body:
Frame, suspension (front and rear independent suspension), steering, brakes (hydraulic disc brakes), wheels, tires, body panels, seats, racks.
Electrical:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, ignition switch, starter motor, indicators, instrumentation, accessory circuits.
Maintenance:
Routine maintenance checks, lubrication points and schedules, filter replacement (oil, air), spark plug service, brake fluid flush, coolant service, battery maintenance.
Diagnostics And Troubleshooting:
System-specific troubleshooting guides, fault code diagnosis (if applicable), electrical system testing, mechanical component diagnosis.
Repair And Rebuild:
Step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and installation of major systems and sub-assemblies.
Depth:
Comprehensive dealership-level technical information, including detailed procedures, specifications, tolerances, and torque values for all repair and maintenance tasks.
Engine Type 400:
Likely a single-cylinder, liquid-cooled, 4-stroke engine. Specific displacement around 375cc to 400cc for the 400 models.
Engine Type 500:
Typically a single-cylinder, liquid-cooled, 4-stroke engine. Specific displacement around 499cc for the 500 models.
Horsepower Range Estimated:
Sportsman 400 models likely produced in the range of 25-30 HP. Sportsman 500 models likely produced in the range of 30-35 HP. (Actual figures vary by specific year and tuning).
Torque Range Estimated:
Dependent on engine size and tuning, but generally robust for utility ATV applications.
Fuel Delivery Early Models:
Carbureted (e.g., Mikuni, Keihin specific to model/year).
Fuel Delivery Later Models:
May include Electronic Fuel Injection (EFI) on some later models within the covered year range, particularly for the 500 series.
Fuel Type:
Unleaded gasoline (typically 87 octane or higher).
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition) with advance timing curves.
Cooling Method:
Liquid-cooled with radiator and fan.
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic CVT (Continuously Variable Transmission).
Gear Selection:
High, Low, Neutral, Reverse.
Drive System:
Shaft drive, typically with Polaris' On-Demand All-Wheel Drive (AWD) system (often referred to as AWD or 4x4).
Belt Maintenance:
Includes procedures for CVT belt inspection, replacement, and sheave maintenance.
Wheelbase Typical:
Approximately 50-52 inches, depending on specific model and year.
Ground Clearance Typical:
Around 10-11 inches, providing good off-road capability.
Dry Weight Typical:
Around 600-700 lbs, depending on model and options.
Towing Capacity:
Typically rated for 660 lbs (299 kg).
Rack Capacity Front:
Approximately 90 lbs (41 kg).
Rack Capacity Rear:
Approximately 180 lbs (82 kg).
Atv Safety Standards:
Designed to meet or exceed industry safety standards for ATVs of its era.
Braking System:
Hydraulic disc brakes on all wheels for reliable stopping power.
Suspension Stability:
Independent front and rear suspension contributes to stability and control over varied terrain.
Rollover Protection:
While not ROPS certified (Roll Over Protection Structure), the manual covers safe operating procedures to mitigate rollover risks.
Operator Training:
Emphasizes safe riding practices, proper gear, and understanding the vehicle's limits.
Instrument Cluster:
Basic digital or analog instrument cluster typically including speedometer, odometer, trip meter, high beam indicator, neutral indicator, and possibly AWD indicator.
AWD System:
Polaris' signature On-Demand All-Wheel Drive (AWD) system automatically engages front wheels when rear wheel slippage is detected.
Accessory Power:
May include accessory power outlets or pre-wiring for lights, winches, and other accessories.
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Specifics in manual.
Air Filter Service:
Inspect every 25 hours, clean/replace as needed. More frequent service in dusty conditions.
Spark Plug Replacement:
Recommended replacement interval typically around 1,000-2,000 miles or 100-200 hours, or as specified by the manual.
Engine Oil Type Viscosity:
SAE 20W-50 or SAE 5W-50 (depending on climate) motorcycle/ATV specific oil meeting API SG or higher. Refer to manual for exact specification and brand recommendations.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type:
Specific gear oil or SAE 80W-90 gear oil for the front and rear gearcases. Manual will detail exact specifications and capacities.
Pvttrailer Arm Issues:
Some models of this era could experience wear on the PVT drive clutch roller arms or premature belt wear if subjected to heavy use or improper operation. Manual covers inspection and replacement.
Electrical Connector Corrosion:
As with many ATVs of this vintage, electrical connectors can be susceptible to corrosion, especially in wet environments. Manual provides wiring diagrams for troubleshooting.
Suspension Wear:
Ball joints, tie rod ends, and bushings are wear items that may require periodic inspection and replacement. Manual details inspection procedures and replacement parts.
Polarishistory:
Polaris has a long-standing history in powersports, originating from snowmobiles and expanding into ATVs and motorcycles, known for innovation and ruggedness.
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris ATVs, recognized for its comfort, independent suspension, and versatility in utility and recreational riding.
Engines In Coverage:
This manual covers the transition and commonality between the 400cc and 500cc engine platforms within this generation of Sportsman and related models.
Manufacturing Origin:
Polaris vehicles are primarily manufactured in the United States.
General Atv Awards:
While specific awards for these exact model years might be difficult to pinpoint, the Polaris Sportsman line consistently received positive reviews for its ride quality, power, and utility features during its production runs, contributing to Polaris' reputation as a leading ATV manufacturer.
Consumer Reviews:
These models are generally well-regarded by owners for their durability and performance in utility and trail riding, often cited in enthusiast forums and reviews from the period.
