Target User:
Professional mechanics, ATV technicians, and experienced DIY enthusiasts.
Manual Value Proposition:
Offers the same detailed, factory-level information as professional workshop manuals, without ongoing costs or restrictions.
Download Policy:
Instant download, no expiry dates, no additional fees.
Licensing:
Lifetime usage rights on unlimited devices.
Primary Coverage:
Complete Service, Repair, and Troubleshooting Procedures
Estimated Pages:
Hundreds
Manual Classification:
Factory Service Manual / Workshop Manual
Primary Language:
English
Digital Compatibility:
Compatible with Windows and MAC computers, tablets, and smartphones
Engine Systems:
Engine overhaul, tuning, carburetor service, cooling system, lubrication, valve adjustment, ignition system, starting system, fuel system.
Drivetrain Systems:
Transmission service (including gearcase, clutch, and drive system), final drive, driveshafts, CV joints.
Chassis Systems:
Suspension (front and rear), steering system, braking system (hydraulic and mechanical components), wheels, tires.
Electrical Systems:
Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery service, ignition switch, starter motor, instrumentation.
Body And Frame:
Body panel removal and installation, frame inspection, seat assembly, rack systems.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug service, air filter cleaning/replacement, brake fluid flush.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, electrical system troubleshooting, engine performance problems, transmission faults.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major ATV systems.
Rebuilds:
Complete engine rebuild procedures, transmission overhauls, carburetor rebuilding.
Installation:
Instructions for installing genuine Polaris accessories or replacement parts.
Depth Of Information:
Professional-grade, with detailed step-by-step instructions, torque specifications, clearances, and diagnostic flowcharts.
Diagrams And Photos:
Hundreds of detailed photos and exploded diagrams illustrating disassembly, reassembly, and component identification.
Engine Type:
4-Stroke, Liquid-Cooled (typically for 500 model), Air-Cooled (typically for 335 model)
Displacement Sportsman 335:
Approximately 335cc
Displacement Sportsman 500:
499cc
Bore X Stroke Sportsman 500:
93.0 mm x 73.0 mm (typical)
Compression Ratio Sportsman 500:
9.0:1 (typical)
Horsepower Sportsman 500:
Approx. 26-28 HP (peak, dependent on tuning and specific configuration)
Torque Sportsman 500:
Approx. 28-30 lb-ft (peak, dependent on tuning and specific configuration)
Carburetor Sportsman 500:
Mikuni BSR42 (typical)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
3.2 US gallons (approx. 12.1 liters)
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive System:
Shaft Drive (2WD/4WD selectable on some models)
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Length:
82.0 in (approx. 208.3 cm)
Width:
45.0 in (approx. 114.3 cm)
Height:
47.0 in (approx. 119.4 cm)
Dry Weight Sportsman 500:
570 lbs (approx. 258.5 kg)
Ground Clearance:
4.5 in (approx. 11.4 cm)
Towing Capacity:
1500 lbs (approx. 680 kg)
Rack Capacity Front:
90 lbs (approx. 40.8 kg)
Rack Capacity Rear:
180 lbs (approx. 81.6 kg)
Braking System:
Hydraulic disc brakes (front and rear), mechanical rear brake actuator.
Parking Brake:
Integrated into the transmission/drivetrain or a separate caliper mechanism.
Lighting:
Dual headlights, taillight/brake light.
Operator Controls:
Handlebar throttle, brake lever, gear selector.
Instrumentation:
Digital speedometer, odometer, trip meter, fuel gauge (on some models), indicator lights for 2WD/4WD, oil pressure, high beam.
Engine Braking:
Standard feature of the PVT system, providing downhill braking assistance.
Diagnostic Ports:
On-board diagnostics (OBD) capabilities for advanced troubleshooting accessible via specific connectors.
Oil Change Interval:
Every 50-100 hours of operation or annually, whichever comes first (refer to manual for exact details).
Air Filter Service:
Check every 25 hours, clean/replace as needed.
Spark Plug Replacement:
Recommended every 100-200 hours or as per manual specifications.
Engine Oil Type Sportsman 500:
SAE 20W-50 API SG or higher (check manual for specific viscosity and API rating).
Engine Oil Capacity Sportsman 500:
Approx. 2.5 US quarts (2.4 liters) with filter change.
Transmission Gearcase Oil:
Polaris AGL Synthetic Gearcase Lubricant or equivalent API GL-4, SAE 75W-90.
Gearcase Oil Capacity:
Approx. 15.5 US fluid ounces (0.46 liters).
Coolant Type:
Ethylene Glycol based antifreeze (e.g., 50/50 mix with distilled water for liquid-cooled models).
Common Wear Items:
Drive belts in the PVT system, wheel bearings, tie rod ends, brake pads.
Potential Engine Issues:
Carburetor tuning or clogging, occasional stator failures, exhaust leaks.
Electrical Concerns:
Corrosion on connectors, battery terminal issues, CDI unit or voltage regulator failure.
Manufacturer History:
Polaris Industries Inc. is a long-standing American manufacturer known for its pioneering work in snowmobiles and its expansion into ATVs, UTVs, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a flagship model for Polaris, renowned for its comfort, independent suspension, and utility-focused design since its introduction.
Manufacturing Location:
Primarily manufactured in the United States.
