Target User:
Owners, Technicians, Enthusiasts involved in repair and maintenance of Polaris Sportsman ATVs
Competitors 2005 2006:
Can-Am Outlander, Honda FourTrax/Rancher, Yamaha Grizzly, Kawasaki Prairie
Vehicle Strengths:
Proven reliability, Versatile for work and recreation, Comfortable ride, Strong towing capacity
Manual Value Proposition:
Empowers users with the knowledge to perform comprehensive maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance.
Powertrain:
Engine (400cc, 499cc), Transmission, Drivetrain (AWD/2WD systems)
Chassis:
Suspension (front and rear), Steering, Brakes (hydraulic disc), Frame
Electrical:
Ignition system, Lighting, Charging system (stator, regulator/rectifier), Battery, Starter motor, Wiring diagrams
Fuel System:
Carburetor (Mikuni BS34/BS36), Fuel pump, Fuel tank, Fuel lines
Body And Trim:
Body panels, Seat, Racks, Handlebars, Controls
Maintenance:
Routine inspections, Oil changes, Filter replacements, Spark plug servicing, Valve adjustments
Diagnostics:
Troubleshooting guides for common problems, Symptom-based diagnosis
Repair:
Engine overhaul, Transmission repair, Suspension component replacement, Brake system service, Electrical component repair
Assembly Disassembly:
Step-by-step instructions for dismantling and reassembling major components
Depth:
Comprehensive diagnostic procedures, detailed repair instructions, complete overhaul specifications
Engine Type:
4-stroke, Single-cylinder, SOHC
Displacement:
375cc (approximate)
Engine Type:
4-stroke, Single-cylinder, SOHC
Bore X Stroke:
92mm x 74mm
Horsepower Estimated:
30-35 HP (approximate, at crankshaft)
Torque Estimated:
35-40 ft-lbs (approximate, at crankshaft)
Carburetor 400:
Mikuni BS34
Carburetor 500:
Mikuni BS36
Fuel Type:
Unleaded gasoline (87 octane minimum)
Oil Type Engine:
SAE 10W-40, API SG or higher
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled
Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse
Drive System:
Shaft Drive
Selectable 4Wd:
Yes (On Demand All-Wheel Drive)
Transmission Fluid Type:
Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 API GL-5)
Atv Safety Standards:
Compliance with ANSI B71.1-2003 standards for ATVs
Braking System:
Hydraulic disc brakes, front and rear
Lighting:
Dual 35W headlights, 40W taillight/brakelight
Handlebar Design:
Ergonomic grips and controls for safe operation
Infotainment System:
N/A (Basic utility vehicle, no integrated infotainment)
Lighting Technology:
Halogen bulbs
Instrumentation:
Analog speedometer, odometer, trip meter, fuel gauge, tachometer, gear indicator, 4WD indicator
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first
Air Filter Inspection:
Every 25 hours or 3 months
Spark Plug Replacement:
Every 100 hours or 12 months
Valve Clearance Check:
Every 100 hours or 12 months
Engine Oil Capacity:
Approx. 1.9 US quarts (1.8 Liters) with filter change
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water
Common Wear Items:
Drive belts (PVT), wheel bearings, tie rod ends, brake pads
Carburetor Tuning:
Occasional need for carburetor cleaning and adjustment due to fuel quality and usage patterns
Electrical Connections:
Corrosion or looseness in electrical connectors, especially in wet environments
Manufacturer:
Polaris Industries Inc., founded in 1954
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings since its introduction, known for its comfort, capability, and utility.
Manufacturing Location:
Polaris manufacturing facilities in the USA
