Market Segment:
Entry-level to mid-range utility ATV
Target Audience:
Recreational riders, small farm operators, hunters, utility users.
Key Competitors:
Honda Foreman, Yamaha Kodiak, Suzuki King Quad, Arctic Cat 400/500 models of similar vintage.
Vehicle Highlights:
Rookie of the Year award (1996 for Sportsman 4x4), Polaris's first modern automatic transmission ATV, robust utility focus, independent rear suspension (IRS) introduced on later models.
Engine Systems:
Engine overhaul, top-end repair, cylinder head, piston, crankshaft, oil pump, lubrication, cooling system, carburetor tuning and overhaul, fuel delivery.
Drivetrain Systems:
Transmission (PVT/CVT) operation and service, gearcase inspection and repair, drive clutch, driven clutch, drive belts, chain case, differential, AWD system (where applicable).
Electrical Systems:
Wiring diagrams, ignition system, starting system, charging system (stator, regulator/rectifier), lighting, battery maintenance, switchgear, indicators, AWD engagement system.
Chassis Systems:
Frame inspection and repair, suspension (front and rear shocks, control arms, bushings), steering system (tie rods, knuckles, steering post), brake system (hydraulic lines, calipers, master cylinders, rotors), wheel and tire service.
Bodywork And Plastics:
Removal and installation of body panels, fenders, racks, seat, storage compartments.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements (oil, air), spark plug service, valve adjustments, lubrication points, battery checks, tire pressure and condition checks.
Diagnostic Procedures:
Troubleshooting guides for common symptoms (e.g., starting issues, poor performance, braking problems), electrical system diagnostics, carburetor troubleshooting, clutch issues.
Repair Procedures:
Complete engine rebuild, transmission overhaul, brake system repair, suspension component replacement, steering system service, electrical component replacement.
Special Tool Procedures:
Identification and usage of specialized tools required for specific maintenance and repair tasks.
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and detailed disassembly/assembly instructions.
Engine Type 400:
4-stroke, SOHC, Single-Cylinder
Engine Displacement 400:
375cc (approximate)
Engine Type 500:
4-stroke, SOHC, Single-Cylinder
Engine Displacement 500:
499cc (approximate)
Horsepower Output Typical:
26-30 HP (approximate, model dependent)
Torque Output Typical:
30-35 lb-ft (approximate, model dependent)
Carburetor Type:
Mikuni or Keihin (specific model variant dependent), typically a single downdraft carburetor.
Fuel Type:
Unleaded gasoline, 87 octane recommended
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission / CVT)
Drive Modes:
2WD/4WD selectable (often on-the-fly), some models feature AWD (All-Wheel Drive) activated by front wheel slippage.
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P) - controlled by a single lever.
Clutch System:
Primary (Drive) clutch and Secondary (Driven) clutch with belt drive.
Atv Safety Standards:
Adheres to ANSI/SVIA standards for all-terrain vehicles.
Braking System:
Hydraulic disc brakes (front and rear), often single lever front/rear brake application or separate controls.
Lighting:
Headlights, taillight/brake light.
Throttle Limiter:
Often includes a thumb throttle with a stop screw for speed limitation, particularly for younger riders.
Oil Change Interval:
Every 100 hours or annually, whichever comes first.
Air Filter Service:
Clean every 25 hours, replace every 100 hours or as needed based on conditions.
Spark Plug Replacement:
Every 100 hours or annually.
Valve Adjustment Interval:
Every 100 hours or annually.
Engine Oil Type:
Polaris Premium 2W-40 Synthetic or SAE 20W-50 API SG or higher.
Engine Oil Capacity:
Approx. 1.6 quarts (1.5 liters) with filter change.
Transmission Fluid Type:
Polaris Angle Drive Fluid (PS-4) or SAE 80W-90 hypoid gear oil.
Transmission Fluid Capacity:
Approx. 0.5 quarts (0.47 liters) for the transmission/gearcase.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Drive belt wear/failure, suspension bushings, tie rod ends, wheel bearings, starter solenoid.
Engine Trouble Areas:
Carburetor clogging, stator failure (loss of spark/charging), oil leaks from crank seals.
Transmission Trouble Areas:
PVT belt slippage, drive clutch roller wear, driven clutch spring fatigue.
Polariss Atv History:
Polaris Industries has a long history in powersports, entering the ATV market in the early 1980s and becoming a major player.
Sportsman Introduction:
The Sportsman line was launched in 1993, revolutionizing the ATV market with features like independent rear suspension (IRS) and comfortable seating, setting a benchmark for utility ATVs.
1996-2003 Features:
This era saw the introduction and refinement of the 400 and 500cc models, solidifying Polaris's reputation for powerful engines and comfortable ride quality. Key updates included refinements to the PVT system and the introduction of the AWD system on some models.
Manufacturing Location:
Roseau, Minnesota, USA
