Segment:
Entry-level to mid-range utility All-Terrain Vehicles (ATVs)
Target Audience:
Recreational riders, utility users, farmers, hunters, and general trail riders
Competitors:
Yamaha Kodiak, Honda Foreman/Rancher, Can-Am Outlander/Outlander MAX, Kawasaki Brute Force
Value Proposition:
Offers a balance of Polaris's renowned handling and feature set at a more accessible price point compared to larger displacement models.
Powertrain Flexibility:
Covers multiple engine displacements (400, 450, 500cc), indicating common chassis and system designs across these variants.
Engine:
Engine assembly, disassembly, diagnosis, performance tuning, cooling system, lubrication system, fuel system, ignition system, starting system
Transmission:
PVT (Polaris Variable Transmission) operation, maintenance, belt inspection and replacement, clutch service, gearbox maintenance
Drivetrain:
All-Wheel Drive (AWD) system, On-Demand AWD, differential service, drive shafts, U-joints, wheel bearings
Brakes:
Hydraulic brake system, caliper service, pad replacement, master cylinder, brake fluid specifications, bleeding procedures
Electrical:
Wiring diagrams, lighting system, battery service, charging system, starter motor, ignition switch, accessories, diagnostic trouble codes (DTCs)
Suspension:
Front and rear suspension components, shock absorber adjustment and replacement, bushings, ball joints, steering components
Chassis And Body:
Frame inspection, body panel removal and installation, seat, handlebars, racks, plastics
Fuel And Emissions:
Fuel tank, fuel pump, fuel filter, carburetor/EFI system (depending on model variant), emission control components
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, greasing points, battery care, belt inspection
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides
Repair And Overhaul:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and calibration
Specifications:
Torque specifications for all fasteners, clearances, measurements, fluid capacities, electrical specifications
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics
Engine Type:
4-stroke, SOHC, 2-valve (typical for these displacements)
Displacement 400:
Approximately 375cc - 400cc (Polaris often uses nominal figures)
Displacement 450:
Approximately 455cc
Displacement 500:
Approximately 499cc
Cooling System:
Liquid-cooled
Bore X Stroke:
Varies by specific engine, manual will detail this
Compression Ratio:
Varies by specific engine, manual will detail this (typically around 9.0:1 to 10.5:1)
Horsepower:
Estimated 28-32 HP (for 400/450 models), 30-36 HP (for 500 models) - actual figures vary and are detailed in the manual
Torque:
Estimated 25-30 lb-ft (for 400/450 models), 30-35 lb-ft (for 500 models) - actual figures vary and are detailed in the manual
Fuel Delivery:
Fuel Injection (EFI) for most 2012-13 models, potentially carburetors on earlier 400 variants not covered by this specific manual.
Fuel Type:
Unleaded gasoline, minimum 87 octane
Type:
Polaris Variable Transmission (PVT) Automatic
Gears:
High, Low, Neutral, Reverse, Park
Drive Modes:
2WD/4WD On-Demand
Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 hypoid gear lubricant for specific gearcase applications)
Gearcase Capacity:
Refer to manual for exact capacity, typically around 1.0-1.2 liters
Wheelbase:
Approximately 50.5 inches (128.3 cm)
Length:
Approximately 81 inches (205.7 cm)
Width:
Approximately 46 inches (116.8 cm)
Height:
Approximately 48 inches (121.9 cm)
Front Rack Capacity:
200 lbs (90.7 kg)
Rear Rack Capacity:
400 lbs (181.4 kg)
Dry Weight:
Approximately 650-680 lbs (295-308 kg)
Towing Capacity:
1500 lbs (680 kg)
Total Vehicle Capacity With Rider:
1000 lbs (453.6 kg)
Rollover Protection:
ATVs are not designed with rollover protection in the same manner as cars. Safe operation is paramount, and the manual will emphasize this.
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
Integral to the PVT system, aids in downhill deceleration.
Lighting:
Dual headlights, brake light, taillight.
Ergonomics:
Handlebar design for control, comfortable seating position.
Display:
Digital instrument cluster displaying speed, RPM, fuel level, gear position, odometer, trip meter, AWD mode, and warning lights.
Drive System:
On-Demand AWD system automatically engages front wheels when rear wheels lose traction.
Charging:
Typically includes a DC power outlet (cigarette lighter style) for charging accessories.
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Air Filter Cleaning:
Every 25 hours or as needed in dusty conditions.
Spark Plug Replacement:
Refer to manual; typically around 100 hours or as recommended by plug manufacturer.
Transmission Oil Change:
Every 200 hours or 24 months.
Engine Oil:
Polaris PS-4 5W-50 Full Synthetic 4-Stroke Oil (or equivalent API SG/SH/SJ rated oil)
Coolant:
Polaris Premium 2-Stroke Synthetic Oil is NOT used here, it's 4-stroke. Use a 50/50 mix of Polaris Premium Antifreeze/Coolant or equivalent ethylene glycol-based coolant with distilled water.
Engine Oil Capacity:
Refer to manual; typically around 2.0-2.2 liters with filter change.
Coolant Capacity:
Refer to manual; typically around 1.8-2.0 liters.
Pvttemp Light:
The PVT (Primary Drive Clutch) temperature warning light can illuminate under heavy load or extreme heat, requiring inspection of clutch components and airflow. The manual will guide troubleshooting.
Electrical Connections:
Corrosion or loose connections in electrical harnesses, especially in wet environments, can lead to intermittent issues. The manual's wiring diagrams are crucial.
Suspension Wear:
Bushings and ball joints can wear over time, especially with aggressive use. Regular inspection and lubrication are advised. The manual details inspection points.
Heritage:
Polaris has a long history in the powersports industry, known for pioneering the modern ATV market. The Sportsman line is a cornerstone of their off-road offerings.
Lineage:
The Sportsman line has evolved significantly since its introduction, with continuous improvements in engine technology, suspension, and rider comfort. The 400/450/500 models represent a popular mid-range offering in the evolution.
Manufacturing Location:
Primarily manufactured in the USA by Polaris.
