Segment:
Mid-size utility ATV
Target Audience:
Recreational riders, utility users, farmers, hunters.
Competitors:
Honda FourTrax, Yamaha Kodiak, Kawasaki Prairie, Suzuki King Quad.
Feature 1:
Independent front suspension (IRS) for improved ride comfort and handling.
Feature 2:
On-Demand True All-Wheel Drive (AWD) system.
Feature 3:
Towing and hauling capability.
Engine Mechanical:
Full engine overhaul, disassembly, assembly, inspection, and repair procedures for both 400 and 500cc engines.
Fuel System:
Carburetor (likely Mikuni or Keihin) tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel tank.
Ignition System:
CDI, spark plug specifications, coil testing, timing procedures.
Cooling System:
Radiator, fan, coolant specifications, thermostat, water pump.
Transmission Drivetrain:
PVT (Polaris Variable Transmission) clutch inspection, maintenance, belt replacement, drive clutch, driven clutch, final drive, differential.
Suspension:
Front and rear suspension geometry, shock absorber adjustment and replacement, bushings, ball joints.
Steering:
Handlebar, steering shaft, tie rods, wheel alignment procedures.
Braking System:
Hydraulic brake system, caliper service, pad replacement, master cylinder, brake fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, starter motor, alternator/stator, battery specifications, lighting system, fuses, relays, ignition switch.
Chassis Frame:
Frame inspection, welding repairs (if applicable), component mounting.
Bodywork Plastics:
Fender removal and installation, seat, racks, trim components.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures.
Diagnostics:
Electrical system diagnostics, sensor testing, wiring continuity checks.
Depth:
Comprehensive, factory-level detail covering routine maintenance to complete engine rebuilds.
Illustrations:
Detailed, step-by-step illustrations and diagrams.
Torque Specifications:
Inclusion of precise torque values for all critical fasteners.
Clearances:
Specifications for internal engine and drivetrain component clearances.
Engine Type 400:
4-stroke, SOHC, 2-valve, single-cylinder
Engine Displacement 400:
Approx. 375cc (specific factory specs needed for precise figure)
Engine Type 500:
4-stroke, SOHC, 2-valve, single-cylinder
Engine Displacement 500:
Approx. 499cc (specific factory specs needed for precise figure)
Horsepower Range:
Estimated 20-30 HP (depending on exact model and tuning)
Torque Range:
Moderate low-end torque for pulling power.
Fuel Delivery:
Carbureted (likely Mikuni BSR series)
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Fuel Tank Capacity:
Typically around 3.3 - 3.7 gallons (check manual for exact)
Transmission Type:
Polaris Automatic Variable Transmission (PVT) with Engine Braking
Drive Modes:
High, Low, Neutral, Reverse
Optional Transmissions:
N/A (PVT was standard for this model)
Clutch System:
Automatic Centrifugal Clutch (Drive Clutch) and Variable Sheave Driven Clutch
Final Drive:
Shaft Drive with sealed U-joints, rear differential.
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 75W-90 synthetic)
Length:
Approx. 80-83 inches (check manual for exact)
Width:
Approx. 46-48 inches (check manual for exact)
Height:
Approx. 47-50 inches (check manual for exact)
Wheelbase:
Approx. 50.5 - 51 inches (check manual for exact)
Dry Weight:
Approx. 550-600 lbs (check manual for exact)
Ground Clearance:
Approx. 10.25 - 11 inches (check manual for exact)
Front Rack Capacity:
Typically 100 lbs
Rear Rack Capacity:
Typically 200 lbs
Towing Capacity:
Typically 1,225 lbs
Atv Safety Standards:
Meets ANSI and SFI standards for ATVs.
Braking System:
Hydraulic disc brakes, front and rear.
Engine Braking:
PVT system provides engine braking for downhill control.
Lighting:
Dual 25W handlebar-mounted headlights, 35W tail/brake light.
Rollover Protection:
N/A (Standard ATV design, operator training is crucial).
Oil Change Interval:
Typically every 100 hours or 6 months (refer to manual for precise intervals and conditions).
Air Filter Cleaning:
Frequent inspection and cleaning recommended, especially in dusty conditions.
Spark Plug Replacement:
Typically at 100-hour intervals or as needed based on inspection.
Transmission Fluid Change:
Typically every 200 hours or 12 months.
Engine Oil Type:
Polaris PS-4 5W-50 Full Synthetic 4-Cycle Engine Oil (or equivalent meeting API SG or higher, JASO MA rated).
Engine Oil Capacity:
Approx. 2.0 - 2.3 quarts (check manual for exact with filter change).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant Type:
Ethylene glycol based antifreeze (e.g., 50/50 mix with distilled water).
Common Wear Item 1:
PVT Belt: Prone to wear and failure if overheated or damaged, requiring timely replacement.
Common Wear Item 2:
Bushings and Ball Joints: Suspension components can wear over time, affecting steering and ride quality.
Common Wear Item 3:
Wiring Harness Issues: Like many vehicles of this era, intermittent electrical issues can arise from worn or damaged wiring.
Carburetor Cleaning:
Carburetors can become clogged with fuel deposits if the ATV sits for extended periods; regular cleaning and fuel stabilizer use are recommended.
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris, known for its comfort, utility, and off-road capability.
2005 Updates:
While specific year-over-year changes for 2005 require detailed spec sheets, this generation typically featured the Polaris Variable Transmission (PVT) and IRS.
Manufacturing Location:
Primarily manufactured by Polaris in the USA.
