Atv Segment Positioning:
The Polaris Magnum 500 2x4 HDS was positioned as a capable utility ATV, known for its reliable design and ease of maintenance, making it suitable for farm work, trail riding, and general recreational use.
Key Competitors 2002:
Competed with models from Honda (e.g., FourTrax Foreman), Yamaha (e.g., Kodiak), and Suzuki (e.g., KingQuad) in the 500cc utility ATV class.
Atv Design Philosophy:
Emphasizes reliable design, simple construction, and ease of repair, promoting DIY maintenance and longevity.
Manual Benefit Proposition:
Provides essential knowledge for cost-effective home maintenance and repair, prolonging ATV life and enhancing owner understanding of mechanical components.
Engine Systems:
Cooling System, Fuel System, Oil System, Carburetor, Oil Pump, Piston and Crankshaft, Crankcase and Cylinder, Recoil Starter, Magneto, Starting Motor.
Drivetrain Systems:
Front Drive, Front Tightener, CV Joint – BTB, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase/Brake and Chain Cover Mounting, Rear Wheel Drive, Gearcase, Gear Selector.
Chassis And Body Systems:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Decals, Front Rack and Bumper Mounting, Engine Mounting, Exhaust System, Fuel Tank, Air Box, Front Strut, A-Arm/Strut Mounting, Center Tightener, Swing Arm/Shock Mounting.
Braking Systems:
Front Brake, Rear Brake.
Electrical Systems:
Electrical/Taillight.
Control Systems:
Controls -- Throttle Assembly/Cable, Controls - Master Cylinder/Brake Line, Steering Post, Handlebar and Headlight Pod.
Maintenance Procedures:
Routine maintenance tasks, including oil changes, spark plug replacement, filter replacement, and inspections of various systems (shift linkage, steering, suspension, coolant, fuel, drive belts, engine mounts).
Repair Procedures:
Detailed repair procedures for all covered systems, supported by exploded diagrams and part number lists for easy identification and replacement.
Part Identification:
Extensive use of exploded diagrams and part number lists to facilitate accurate part identification for maintenance and repairs.
Depth Of Coverage:
Covers from basic maintenance to detailed component-level repairs, enabling home mechanics to perform a wide range of service tasks.
Printability:
Printable pages, allowing users to print only necessary sections.
Searchability:
Assumed searchable text within the PDF for efficient information retrieval.
Graphic Quality:
Includes exploded diagrams, indicating good quality graphics for technical illustration.
Binding Type:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve
Bore X Stroke:
Not specified in provided text, but typically around 92.0 mm x 73.5 mm for this engine.
Compression Ratio:
Not specified in provided text.
Horsepower:
Typically around 30-35 HP, specific to 2002 model not detailed here.
Torque:
Not specified in provided text.
Carburetor Type:
Mikuni BSR42
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Fuel Capacity:
Typically around 3.6 gallons (13.6 liters).
Oil Type:
SAE 20W-50 motorcycle oil with API SG or higher rating.
Oil Capacity:
Approximately 2.1 US quarts (2.0 liters) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixed with distilled water (50/50 ratio recommended).
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse.
Optional Transmission Features:
N/A for this model.
Clutch System:
Dual clutch system (Drive and Driven) for CVT operation.
Gearcase Oil Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent.
Gearcase Oil Capacity:
Approximately 0.75 US quarts (0.7 liters).
Overall Length:
Approximately 81.8 inches (207.8 cm).
Overall Width:
Approximately 46.0 inches (116.8 cm).
Overall Height:
Approximately 47.0 inches (119.4 cm).
Wheelbase:
Approximately 50.0 inches (127.0 cm).
Dry Weight:
Approximately 566 lbs (257 kg).
Ground Clearance:
Approximately 9.25 inches (23.5 cm).
Rack Capacity Front:
Approximately 100 lbs (45 kg).
Rack Capacity Rear:
Approximately 200 lbs (90 kg).
Towing Capacity:
1500 lbs (680 kg).
Tire Size Front:
AT 25 x 8-12
Tire Size Rear:
AT 25 x 11-12
Wheel Bolt Pattern:
4x110 mm (Common for Polaris ATVs of this era).
Atv Safety Standards:
Designed to meet applicable ANSI standards for recreational off-highway vehicles.
Braking System Type:
Hydraulic disc brakes front and rear, plus parking brake.
Engine Braking:
PVT system provides engine braking in lower gears.
Lighting:
Dual headlights, taillight/brake light.
Handlebars:
Tapered handlebars with comfortable grip design.
Seat:
Ergonomic seat for rider comfort and control.
Oil Change Interval:
Refer to manual for specific mileage/hour intervals, but generally every 100 hours or annually.
Air Filter Cleaning Replacement:
Inspect and clean every 25 hours, replace as needed.
Spark Plug Replacement:
Replace every 100 hours or annually, or as per manual recommendations.
Drive Belt Inspection Replacement:
Inspect regularly for wear and damage, replace as needed based on mileage or condition.
Engine Oil Specification:
SAE 20W-50, API SG or higher.
Gearcase Oil Specification:
Polaris AGL Synthetic Gearcase Lubricant or equivalent.
Coolant Specification:
50/50 mix of ethylene glycol antifreeze and distilled water.
Common Wear Items:
Drive belts, CV boots, wheel bearings, and brake pads are common wear items on ATVs of this vintage.
Carburetor Maintenance:
Carburetors may require periodic cleaning and adjustment due to fuel quality or debris.
Cooling System Care:
Regular coolant checks and flushing are important to prevent overheating and corrosion.
Polaris Atv Legacy:
Polaris has a long-standing history in the powersports industry, pioneering many innovations in ATV technology and design, establishing itself as a leading manufacturer.
Magnum Series Evolution:
The Magnum series was a popular line for Polaris, evolving over the years to incorporate larger engines, improved suspension, and enhanced utility features, with the 500cc engine becoming a mainstay.
Production Period:
The 2002 model year falls within a period of significant growth and refinement for Polaris ATVs.
