Segment:
Mid-size utility ATV, popular for recreational riding, farming, and light work.
Competitors:
Competes with models like the Honda FourTrax Foreman, Yamaha Kodiak, Suzuki KingQuad, and Kawasaki Brute Force.
Features:
Known for its reliable engine, comfortable ride, independent suspension, and Polaris's proprietary On-Demand All-Wheel Drive system.
Value:
Provides factory-level diagnostic and repair information, empowering owners to perform maintenance and repairs, saving significant costs compared to dealership services.
Engine:
Complete coverage: disassembly, inspection, assembly, troubleshooting, diagnostics, specifications.
Transmission:
Complete coverage: automatic transmission, drive system (AWD/2WD), gear case, belt replacement, troubleshooting.
Chassis And Body:
Comprehensive coverage: frame, suspension (front and rear), steering, braking system, body panels, seat, handlebars, lighting.
Electrical System:
Detailed coverage: battery, charging system, ignition system, starter, lighting, accessories, wiring diagrams, troubleshooting.
Fuel System:
Complete coverage: fuel tank, fuel pump, carburetor (or EFI if applicable to specific sub-models), fuel lines, troubleshooting.
Cooling System:
Detailed coverage: radiator, fan, hoses, coolant specifications, troubleshooting.
Estimated Pages:
Approximately 300-500 pages (typical for a factory workshop manual of this type, exact number may vary).
Type:
Factory Workshop Manual / Service Manual / Repair Manual
Primary Language:
English
Download Format:
PDF Download
Searchable Text:
Likely to be searchable text within the PDF for efficient information retrieval.
Printable:
Yes, designed for printing specific sections or the entire manual.
Powertrain:
Engine, transmission, drive shafts, differentials, axles.
Chassis:
Frame, suspension components (shocks, control arms, bushings), steering system, wheel bearings.
Braking System:
Hydraulic brake system, calipers, master cylinder, brake lines, brake pads, rotors.
Electrical:
Ignition, charging (stator, voltage regulator), starting (starter motor, solenoid), lighting (headlights, taillights, brake lights), indicators, switches, wiring diagrams.
Fuel Delivery:
Fuel pump, fuel filter, fuel tank, fuel lines, carburetor or EFI system components.
Cooling:
Radiator, cooling fan, thermostat, coolant hoses, coolant specifications.
Exhaust:
Exhaust pipes, muffler, heat shields.
Body And Trim:
Front and rear racks, fenders, body panels, seat, handlebars, grips, controls.
Preventative Maintenance:
Oil changes, filter replacements, lubrication points, chain adjustment, spark plug service, battery maintenance.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues across all systems.
Repair And Rebuild:
Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Component Adjustment:
Carburetor adjustment, throttle cable adjustment, brake adjustment, suspension adjustments.
Wiring Diagrams:
Complete electrical system wiring diagrams with component locations and wire color coding.
Special Tools:
Identification and usage instructions for any specialized tools required for repairs.
Diagnostics:
Advanced diagnostic procedures, including troubleshooting charts and electrical testing methods.
Specifications:
Torque specifications for all fasteners, clearances, tolerances, fluid capacities, and electrical values.
Rebuild Instructions:
Complete engine and transmission rebuild procedures.
Exploded Views:
Detailed exploded view diagrams illustrating component relationships and part identification.
Engine Type:
4-stroke, SOHC, 1-cylinder
Displacement:
499cc (499 cubic centimeters)
Bore X Stroke:
92mm x 75mm (approximate, refer to manual for exact figures)
Cooling System:
Liquid-cooled
Compression Ratio:
9.5:1 (typical, refer to manual for exact figures)
Horsepower:
Approx. 28-30 HP (at crankshaft, varies slightly by source and trim)
Torque:
Approx. 30-32 lb-ft (at crankshaft, varies slightly by source and trim)
Fuel Delivery:
Carbureted (likely Mikuni BSR 42mm for most models, but check manual for specific variations)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Ignition System:
CDI (Capacitor Discharge Ignition)
Engine Oil Capacity W Filter:
Approx. 2.8 U.S. quarts (2.65 liters) - verify in manual
Spark Plug Type:
NGK CR8E (common, verify in manual)
Transmission Type:
Automatic, PVT (Polaris Variable Transmission) with engine braking
Drive System:
Shaft Drive, On-Demand AWD/2WD
Gear Selection:
High, Low, Neutral, Reverse, Park
Transmission Fluid:
Polaris AGL Premium Synthetic Gearcase Oil or equivalent (verify in manual for specific gearbox applications)
Gearcase Fluid Capacity:
Approx. 0.5 U.S. quarts (0.47 liters) - verify in manual
Safety Certification:
Meets ANSI standards for recreational trail riding (when used as intended and with proper safety gear).
Braking System:
Hydraulic disc brakes front and rear, engine braking.
AWD System:
Polaris's On-Demand All-Wheel Drive for enhanced traction.
Lighting:
Dual 25W headlights, 8W taillight, 27W brake light.
Handlebar Protection:
Integrated handguards or knuckle guards (depending on trim).
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Cleaning:
Every 25 hours or 3 months, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 100 hours or 1 year.
Belt Inspection:
Inspect every 50 hours or 6 months.
Engine Oil:
SAE 5W-50 Synthetic (Polaris recommends their brand, but compatible synthetics are acceptable - check manual)
Coolant:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water (Polaris recommends their specific coolant)
Brake Fluid:
DOT 3 or DOT 4 brake fluid (verify in manual)
Common Problems:
Potential issues can include CVT belt wear/slipping, occasional carburetor gumming (if not run regularly), and general wear-and-tear on suspension components common to all ATVs.
Best Practices:
Regular cleaning, proper storage, using fresh fuel, and adhering to the maintenance schedule are crucial for longevity.
Brand History:
Polaris Inc. has a long history in powersports, dating back to 1954, and is a pioneer in the ATV market.
Sportsman Lineage:
The Sportsman line is one of Polaris's most successful and enduring ATV series, known for its utility and comfort.
Manufacturing Location:
Primarily manufactured in Spirit Lake, Iowa, USA, and Roseau, Minnesota, USA.
