Segment:
Utility ATV (All-Terrain Vehicle)
Key Competitors 2002:
Honda Foreman, Yamaha Kodiak, Suzuki QuadRunner, Kawasaki Prairie
Versatility:
Designed for utility, recreation, and trail riding with robust carrying capacity.
Authenticity:
Genuine factory service manual, ensuring accuracy and completeness.
Engine Mechanics:
Complete engine disassembly, assembly, timing, lubrication, cooling, starting, and charging systems.
Fuel System:
Carburetor adjustment, fuel pump, fuel tank, lines, and filters.
Drivetrain:
Transmission (PVT - Polaris Variable Transmission), final drive, front and rear differentials, driveshafts, and CV joints.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, ball joints, and steering linkage.
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, and rotors.
Electrical System:
Battery, charging system, ignition system, lighting, accessories, and starter motor.
Wiring Diagrams:
Comprehensive, high-quality wiring diagrams for all electrical circuits.
Body And Chassis:
Frame, body panels, racks, and seating.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, and lubrication points.
Troubleshooting:
Diagnostic procedures and common issue resolution.
Repair Procedures:
Step-by-step instructions for component disassembly and reassembly.
Tune Up:
Engine tuning, carburetor synchronization, and ignition timing adjustments.
Technical Data:
Specifications, tolerances, and torque values for all components.
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhauls.
Engine Type:
4-stroke, Single Cylinder
Bore X Stroke:
80mm x 74.4mm
Cooling System:
Liquid-Cooled
Engine Type:
4-stroke, Single Cylinder
Bore X Stroke:
92mm x 76mm
Cooling System:
Liquid-Cooled
Carburetor Type:
Mikuni VM32SS (400), Mikuni BSR42 (500)
Ignition System:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:
2WD/4WD (On-Demand All-Wheel Drive)
Gear Selection:
Automatic (High, Low, Neutral, Reverse, Park)
Fluid Type:
Polaris PS-4 4-stroke Synthetic Oil (refer to manual for specific viscosity and capacity)
Instrumentation:
Digital odometer, speedometer, fuel gauge, 4WD indicator, high/low gear indicator, neutral indicator, reverse indicator, oil light.
Engine Braking:
Integrated engine braking within the PVT system for downhill control.
Charging System:
12V DC electrical system with charging output for battery.
Oil Change Interval:
Every 100 hours or 6 months (refer to manual for precise recommendations).
Air Filter Maintenance:
Inspect every 25 hours, clean/replace as needed (more frequently in dusty conditions).
Spark Plug Replacement:
Refer to manual for recommended interval based on usage.
Engine Oil Type:
Polaris PS-4 4-stroke Synthetic Oil (or equivalent SAE 5W-50).
Engine Oil Capacity:
Refer to manual for specific capacity (typically around 2.1 quarts / 2.0 liters).
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water).
Common Wear Items:
PVT belt, wheel bearings, tie rod ends, ball joints due to demanding use.
Carburetor Tuning:
May require occasional adjustment or cleaning, especially if fuel quality varies.
Polaris History:
Polaris Inc. is an American manufacturer of snowmobiles, ATVs, motorcycles, and UTVs, known for innovation in the powersports industry since 1954.
Sportsman Lineage:
The Sportsman line, introduced in 1993, became a benchmark for utility and comfort in the ATV market, evolving through various engine sizes and feature packages.
Manufacturing Location:
Spirit Lake, Iowa, USA
