Segment:
Recreational and utility ATV market, known for its comfort and touring capabilities.
Target Audience:
Enthusiasts, recreational riders, utility users seeking a reliable and capable touring ATV.
Competitors:
Yamaha Grizzly, Can-Am Outlander, Honda Foreman/Rancher series (depending on specific configuration and intended use).
Engine Type:
500cc class, Electronic Fuel Injection (EFI) for consistent power and easy starting.
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with engine braking.
Suspension Type:
Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) for superior ride comfort and handling.
Storage:
Front and rear racks for carrying gear, often with integrated storage compartments.
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Diagnostics
Secondary Coverage:
Specifications, Wiring Diagrams, Component Identification
Estimated Pages:
Typically 300-600 pages for a comprehensive ATV service manual of this era. Exact count not provided.
Type:
Service and Repair Manual
Purpose:
To guide owners and technicians through maintenance, repair, and troubleshooting procedures.
Language:
English (assumed based on product description language and typical manual availability)
Engine:
Engine assembly, disassembly, tuning, fuel system (EFI), ignition system, cooling system, lubrication system.
Drivetrain:
Transmission (PVT - Continuously Variable Transmission), drive shafts, differentials, final drive.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, bushings, wheel bearings.
Brakes:
Hydraulic brake system, master cylinders, calipers, brake pads, brake lines, rotor maintenance.
Electrical:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition switch, EFI control unit, sensor diagnostics, wiring diagrams.
Fuel System:
Fuel pump, fuel injectors, throttle body, fuel pressure regulator, EVAP system (if applicable).
Body And Chassis:
Frame, plastics, body panels, seat, handlebars, racks, lighting fixtures.
Steering:
Steering column, tie rods, steering rack, universal joints.
Cooling System:
Radiator, fan, coolant, hoses, thermostat.
Preventative Maintenance:
Oil changes, filter replacements, lubrication points, spark plug service, fluid checks, chain/belt adjustment.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for engine performance, electrical issues, starting problems.
Engine Repair:
Top-end rebuild (cylinder, piston, valves), bottom-end rebuild (crankshaft, connecting rod), camshaft inspection and replacement, EFI system diagnostics and repair.
Transmission Repair:
PVT system maintenance and repair, drive clutch and driven clutch service, belt replacement, gearbox inspection.
Electrical Diagnostics:
Reading diagnostic trouble codes (DTCs), testing sensors, checking wiring continuity, starter and charging system testing.
Brake System Service:
Bleeding the brake system, replacing brake pads and rotors, caliper overhaul.
Suspension And Steering Repair:
Ball joint replacement, tie rod end replacement, wheel bearing replacement, shock absorber adjustment and replacement.
Depth:
Comprehensive, covering basic maintenance to complete engine and drivetrain overhauls.
Detail Level:
Includes step-by-step instructions, torque specifications, special tool requirements, and diagnostic procedures.
Engine Type:
4-stroke, Liquid-Cooled, Single-Cylinder
Displacement:
499cc (approximate)
Bore X Stroke:
Specifics not in product description, but typical for this engine class.
Valvetrain:
SOHC (Single Overhead Camshaft)
Horsepower:
Approximately 30-35 HP. Exact figures vary by year and tuning.
Torque:
Specific figures not in product description, but adequate for its class.
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Front Rack Capacity:
Typically 100 lbs (45.4 kg)
Rear Rack Capacity:
Typically 200 lbs (90.7 kg)
Dry Weight:
Approx. 660 lbs (299.4 kg). Actual weight varies with options.
Towing Capacity:
Typically 1,500 lbs (680 kg)
Payload Capacity:
Typically 265 lbs (120 kg)
Safety Certifications:
Certified for Recreational Off-Highway Vehicle Operations (ROV) where applicable. Compliance with EPA standards for emissions.
Braking:
Hydraulic disc brakes front and rear, often with a single lever for front and right-rear, foot pedal for left-rear. Some models may have engine braking for downhill control.
Traction Control:
On-Demand 4WD system for improved traction. Some models may feature ADC (Active Descent Control).
Lighting:
Dual headlights, taillight, brake light.
Operator Interface:
Ergonomic handlebars, comfortable seating position for touring. Handguards may be standard or optional.
Instrumentation:
Digital gauge cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, 4WD indicator, and warning lights.
Efi:
Electronic Fuel Injection for optimized performance and emissions.
Adc:
Active Descent Control (optional on some models) for controlled descents on steep grades.
Accessory Power:
Typically includes a DC power outlet for charging accessories.
Oil Change Engine:
Typically every 100 hours or annually, whichever comes first. Specific interval in manual.
Air Filter Cleaning:
Check every 25 hours, clean/replace as needed. More frequent in dusty conditions.
Spark Plug Replacement:
Typically every 100-200 hours or annually. Check manual for specific plug type and gap.
Pvp Belt Inspection:
Inspect every 50 hours for wear and damage. Replace as needed, typically every 2-3 years or based on mileage/usage.
Engine Oil:
Polaris PS-4 5W-50 Full Synthetic (or equivalent API SG or higher, SAE 5W-50 viscosity).
Coolant:
Ethylene glycol based antifreeze, 50/50 mix with distilled water. Specific Polaris coolant recommended.
Brake Fluid:
DOT 4 brake fluid.
Gearcase Fluid:
Specific Polaris gearcase lubricant or SAE 80W-90 GL-5 gear oil.
Pvp Belt Wear:
Premature belt wear can occur with aggressive riding or improper belt maintenance.
Efi Sensor Issues:
Sensors like the throttle position sensor (TPS) or crank position sensor can sometimes fail, leading to performance issues.
Suspension Bushings:
Wear and tear on suspension bushings is common with regular use, requiring periodic replacement.
