Atv Segment:
Mid-size utility ATV segment
Target Audience:
Recreational riders, hunters, farmers, and general off-road enthusiasts
Key Competitors Era:
Honda FourTrax/Rancher, Yamaha Grizzly, Suzuki KingQuad, Can-Am Outlander
Vehicle Strengths:
Polaris's reputation for power and off-road capability, comfortable seating, user-friendly operation
Manual Value Proposition:
Provides factory-level repair and maintenance information, empowering owners to perform extensive servicing
Manual Scope:
Comprehensive repair and maintenance
Specific Coverage:
Tune-ups, lubrication, major engine rebuilds, transmission rebuilds
Estimated Page Count:
Varies by specific model year and engine, but typically 300-500 pages for comprehensive coverage
Manual Classification:
Factory/Official Service Manual
Digital Format:
Searchable PDF
Engine:
Complete engine disassembly, assembly, inspection, and repair for both 400 and 500cc models
Transmission:
All aspects of transmission repair, including disassembly, inspection, and reassembly
Drivetrain:
4WD system operation, maintenance, and repair, including differential, driveshafts, and CV joints
Fuel System:
Carburetor service, fuel pump, fuel tank, fuel lines, and fuel filter maintenance
Electrical System:
Ignition system, starting system, charging system, lighting, and accessory wiring diagrams and troubleshooting
Cooling System:
Radiator, fan, coolant, and thermostat service
Suspension System:
Front and rear suspension components, including shocks, springs, control arms, and bushings
Braking System:
Hydraulic brake system maintenance, including master cylinder, calipers, brake pads, and brake lines
Steering System:
Steering column, tie rods, and steering linkage service
Body Chassis:
Frame, body panels, seat, handlebars, and rack maintenance and repair
Maintenance:
Scheduled maintenance, lubrication points, filter changes, spark plug replacement
Troubleshooting:
Diagnostic charts and procedures for common issues and performance problems
Repair:
Step-by-step repair instructions for all major mechanical and electrical components
Rebuild:
Detailed instructions for complete engine and transmission rebuilds
Adjustment:
Carburetor adjustment, throttle cable adjustment, brake adjustments
Inspection:
Inspection procedures for critical components and wear items
Depth Of Information:
OEM Specifications (torque values, tolerances, compression ranges), detailed diagrams, and illustrations
User Level:
Suitable for professional mechanics and individuals with basic mechanical knowledge
Visual Aids:
Exploded diagrams, charts, illustrations, and photos for disassembly and reassembly
Engine Type 400:
4-stroke, liquid-cooled, SOHC, single-cylinder
Engine Displacement 400:
Approx. 375cc (Specific displacement may vary slightly by year)
Engine Type 500:
4-stroke, liquid-cooled, SOHC, single-cylinder
Engine Displacement 500:
Approx. 499cc (Specific displacement may vary slightly by year)
Horsepower 500 Est:
Approx. 30-35 HP (Varies by year and tuning)
Torque 500 Est:
Approx. 30-35 ft-lbs (Varies by year and tuning)
Fuel Delivery:
Carbureted (e.g., Mikuni or Keihin models)
Fuel Type:
Unleaded gasoline
Fuel Pressure Chart:
Available within the manual for diagnosis and verification
Compression Ranges:
Specified in manual for diagnostic purposes
Transmission Type:
Automatic Polaris Variable Transmission (PVT)
Drive Modes:
High, Low, Neutral, Reverse
Belt Drive System:
CVT belt drive system requiring regular inspection and replacement
Transmission Fluid:
Specific Polaris AGL (All-Season Gear Lubricant) or equivalent recommended
Length:
Approx. 83 inches (Varies slightly by model year)
Width:
Approx. 46 inches (Varies slightly by model year)
Height:
Approx. 48 inches (Varies slightly by model year)
Dry Weight:
Approx. 600-650 lbs (Varies by model year and features)
Towing Capacity:
Typically around 1,500 lbs
Rack Capacity Front:
Approx. 90 lbs
Rack Capacity Rear:
Approx. 180 lbs
Atv Safety Standards:
Adherence to industry safety standards for ATVs
Braking System Type:
Hydraulic disc brakes (front and rear)
Drive System:
On-demand AWD (All-Wheel Drive) and 2WD selectable
Lighting:
Dual headlights, taillight/brake light
Ergonomics:
Handlebar design for comfortable control
Oil Change Interval:
Typically every 100 hours or annually (refer to manual for exact recommendation)
Air Filter Maintenance:
Frequent checks and cleaning/replacement based on operating conditions
Spark Plug Replacement:
Recommended at specific hour intervals or annually
Engine Oil Type:
Polaris 5W-50 Synthetic or SAE 10W-40 (Refer to manual for exact specification)
Engine Oil Capacity:
Approx. 1.8 liters (Varies slightly)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Belt Wear:
CVT belt wear and slippage are common maintenance items
Carburetor Issues:
Carburetor clogging or needing adjustment due to fuel quality or age
Electrical Connections:
Corrosion or loose electrical connections can cause intermittent issues
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear over time
Polarisfamily Legacy:
Polaris Industries has a long history in recreational and utility vehicles
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, known for its comfort and capability
Xplorer Positioning:
The Xplorer sub-model often emphasized a blend of utility and comfort for longer rides
Production Era:
Models from the early 2000s represent a period of significant ATV development and popularity
