🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400, Sportsman 500 H.O., Sportsman 500 DUSE, Sportsman 500 H.O. DUSE, Sportsman 500 H.O. RSE

Year:

2001

Vehicle Type:

All-Terrain Vehicle (ATV)

Manual Type:

Workshop Service Repair Manual

👋 Introduction

Market Position:

This manual serves as an essential resource for owners and mechanics working on the 2001 Polaris Sportsman line of ATVs, offering dealership-level repair information for DIY enthusiasts and professional technicians alike.

Key Features:

Detailed illustrations, step-by-step instructions, troubleshooting guides, electrical diagrams, and comprehensive coverage of all models, providing an invaluable tool for maintaining and repairing these ATVs.

Competitive Landscape 2001:

Competed against other major ATV manufacturers like Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) in the utility ATV segment.

📋 Manual Details

Coverage Areas:

All models and styles of the 2001 Polaris Sportsman 400, Sportsman 500 H.O., Sportsman 500 DUSE, Sportsman 500 H.O. DUSE, and Sportsman 500 H.O. RSE ATV.

Page Count:

Approximately 400 pages

File Format:

PDF

Accessibility:

Digital Download, Printable

Language:

English

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Coolant, Engine Control System, Emission Control Systems, Drive Shaft, Drive Belt, Differential Case Assy, Cylinder Head Assy, Cylinder Block Assy, Cooling System, Cooling Fan System, Combination Meter, Clutch Unit, Clutch System, Clutch Start Switch Assy, Clutch Release Cylinder Assy, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Charging System, Charcoal Canister, Chain Sub-Assy, Center Stop Lamp Assy, Center Cluster Module Switch, Camshaft Position Sensor, Camshaft, Brake System, Brake Pedal, Brake Master Cylinder, Brake Fluid, Brake Booster, Brake Actuator, Body Repair, Yaw Rate Sensor, Wiring Diagrams, Wire Harness Repair, Wiper Rubber, Wiper And Washer System, Windshield Wiper Switch Assy, Windshield Wiper Motor Assy, Windshield Glass, Window Defogger System, Wheel And Tire System, Water Pump Assy, Valve Clearance, Transmission Wire, Transmission Valve Body, Transmission Revolution Sensor, Transmission Control Cable, Torque Converter Clutch, Tire & Wheel, Throttle Body Assy, Thermostat, Supplemental Restraint System, Sun Roof System, Steering System, Steering Sensor, Steering Column, Starting System, Starter Switch, Starter Assy, Spiral Cable Sub-Assy, Speed Sensor Front, Skid Control Sensor, Side Turn Signal Lamp Assy, Side Air Bag Sensor Assy, Shift Lock System, Shift & Select Lever Shaft, Sfi System, Seat Position Air Bag Sensor, Seat Belt Warning System, Seat Belt, Roof Headlining, Roof Drip Side Finish Moulding, Roof Antenna Pole Sub-Assy, Receiver Condenser Assy, Rear Wiper Rubber, Rear Wiper Motor Assy, Rear Wheel Alignment, Rear Suspension System, Rear Speaker Assy, Rear Shock Absorber Assy, Rear Seat Belt, Rear Door Window Frame Moulding, Rear Door Glass Weatherstrip, Rear Combination Lamp Assy, Rear Coil Spring, Rear Bumper, Rear Brake, Rear Axle Hub, Rear Axle Beam, Radio Receiver Assy, Radiator Assy, Quarter Window Assy, Pulley Compressor Assy, Power Window Control System, Power Steering Link Assy, Power Steering, Power Mirror Control System, Power Door Lock Control System, Passenger Air Bag Assy, Parkneutral Position Switch, Parking Brake Lever, Parking Brake Cable, Output Shaft Assy, Outer Rear View Mirror Assy, Oil Pump, Oil Filter, Manual Transaxle System, Manual Transaxle Oil, Maintenance, Lubrication System, Lighting System, License Plate Lamp Assy, Knock Sensor, Introduction, Instrument Panel, Ignition System, Horn Button Assy, Horn, Hood, Heater Radiator Assy, Workshop, pdf, Instant Download, digital, scanned

Electrical System:

Detailed troubleshooting and repair procedures for the entire electrical system, including ignition, lighting, charging system, starter, and all sensors and switches. Comprehensive wiring diagrams included.

Body Chassis:

Covers body panels, racks, frame inspection and repair, and mounting hardware for all major components.

Fuel System:

Detailed procedures for carburetor cleaning, adjustment, rebuilding, fuel tank removal/installation, and fuel line maintenance.

Exhaust System:

Information on exhaust system inspection, muffler replacement, and mounting.

Ignition System:

Covers spark plug specifications, ignition coil testing, CDI unit diagnostics, and stator testing.

Cooling System:

Radiator maintenance, fan operation testing, thermostat replacement, coolant flush procedures, and leak detection.

Wheels Tires:

Tire pressure recommendations, tire replacement, wheel balancing, and wheel bearing service.

Procedures Included:

Complete disassembly and reassembly procedures, detailed repair instructions, troubleshooting guides, electrical system diagnostics, maintenance procedures, fluid specifications, component replacement, and adjustments.

Engine Overhaul:

Complete engine rebuild procedures, including cylinder head removal/installation, piston replacement, crankshaft service, valve adjustments, and timing component replacement.

Transmission Repair:

Procedures for PVT belt inspection/replacement, clutch assembly service, and troubleshooting transmission engagement issues.

Suspension Steering:

Detailed instructions for servicing front and rear suspension components, steering linkage, tie rods, and wheel bearing replacement.

Carburetor Tuning:

Specific instructions for adjusting fuel-air mixture, idle speed, and troubleshooting common carburetor issues like flooding or lean conditions.

Pvt Maintenance:

Detailed guide on inspecting the primary and secondary clutches, proper belt tensioning, and centrifugal clutch service.

Technical Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds and electrical system diagnostics). Includes detailed illustrations, step-by-step instructions, and critical notes/cautions.

Diagnostic Troubleshooting:

Extensive troubleshooting section with symptom-based diagnostic trees and specific repair steps to identify and resolve common and uncommon issues.

Special Tools:

Highlights necessary special tools required for specific repair procedures, such as clutch holding tools or seal drivers.

📊 Manual Specifications

File Format Details:

PDF, compatible with Windows, Mac, and Linux operating systems. Pages are fully printable without restrictions.

Print Quality:

High quality scans ensuring clarity of text and illustrations, making it suitable for printing specific sections or the entire manual.

Manual Completeness:

100% complete and intact, with no missing or corrupt pages/sections. Covers all aspects of service and repair as per factory specifications.

Illustrations Photos:

Hundreds of detailed illustrations, drawings, and photos to guide users through each repair procedure, including enlarged inset views for critical components.

Instructional Format:

Numbered instructions, detailed sub-steps, and bold figure numbers for easy cross-referencing with illustrations.

Table Of Contents:

Numbered table of contents for quick and easy access to specific information.

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, OHC, V-twin (for 500 models); Single-cylinder (for 400 model, specific configuration not detailed in product info but implied by model name).

Displacement:

499cc (for 500 models). Specific displacement for 400 model not explicitly stated but likely around 400cc.

Fuel Delivery:

Carbureted (specific carburetor model details would be in manual).

Horsepower Torque:

Specific HP/Torque figures not provided in product description, but manual would contain detailed specifications.

Engine Features:

Liquid-cooled, V-twin engine (500cc models) known for its torque and power delivery in off-road applications.OHC design for efficient valve operation.

🔧 Transmission

Transmission Type:

Automatic (PVT - Polaris Variable Transmission).

Drive System:

Shaft drive, likely with options for 2WD/4WD engagement (specifics to be detailed in manual).

Transmission Features:

Includes High/Low range, Neutral, and Reverse gears.

📐 Dimensions

Dry Weight:

Typically around 650-700 lbs for Sportsman 500 models, exact figures for each variant are in the manual.

Gvwr:

Gross Vehicle Weight Rating will be specified in the manual; typically around 1100-1200 lbs for these models.

Towing Capacity:

Typically rated around 1500 lbs, detailed specifications are in the manual.

Cargo Capacity:

Front and rear racks with specified weight limits, detailed in manual.

🛡️ Safety Features

Passive Safety:

Handlebar controls, footwells with heel guards, operator presence lever for throttle engagement.

Active Safety:

Hydraulic disc brakes front and rear, engine braking via PVT system, likely AWD engagement system.

💡 Technology Features

Infotainment System:

Basic analog instruments (speedometer, odometer, fuel gauge, warning lights). No complex infotainment systems.

Driver Assistance Features:

None typically found in this model year; focus is on mechanical and functional operation.

Lighting System:

Dual halogen headlights, taillight, brake light, and likely a work light. Manual covers bulb replacement and electrical system diagnostics.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or 6 months. Manual provides detailed schedule for all maintenance items.

Air Filter Cleaning:

Recommended cleaning and oiling at regular intervals (e.g., 25-50 hours) as detailed in the manual.

Spark Plug Replacement:

Intervals for checking and replacing spark plugs provided in the maintenance schedule.

Engine Oil Type:

SAE 10W-40 or 20W-50 motorcycle specific or ATV oil (check manual for exact Polaris recommendation and API service classification).

Coolant Type:

Ethylene Glycol based antifreeze/coolant (specific mixture ratio and type detailed in manual).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (specific type is crucial and found in the manual).

Gear Case Oil:

Specific gear oil viscosity and type (e.g., SAE 80W-90 GL-5) will be detailed in the manual.

Final Drive Oil:

Likely the same specification as gear case oil for shaft-driven models; confirmed in manual.

Common Issues 2001 Sportsman:

Potential issues common to this era include carburetor tuning, PVT belt wear, starter solenoid failures, and suspension component wear. Manual offers diagnostic procedures for these.

📚 Vehicle History

Brand Heritage:

Polaris is a long-standing American manufacturer known for its innovation in off-road vehicles, including ATVs and snowmobiles.

Model Evolution:

The Sportsman line has been a flagship model for Polaris, continually evolving in features, engine power, and utility since its inception. The 2001 models represent a mature stage in its development, offering robust performance and features.

Production Years For Model Line:

The Sportsman 500 line has been in production for many years prior to and after 2001, with continuous updates and variants.