Category:
All-Terrain Vehicle (ATV)
Target Audience:
Owners, DIY mechanics, service technicians working on Polaris Sportsman ATVs
Competitors:
Honda FourTrax, Yamaha Grizzly, Kawasaki Bayou, Suzuki King Quad
Comprehensive Coverage:
Covers a wide range of model years and repair types for the Sportsman lineup.
Visual Aids:
Abundant with detailed pictures and diagrams to aid understanding.
Practicality:
Printable pages allow for on-the-job reference in various working conditions.
Engine Mechanical:
Engine disassembly, assembly, overhaul, tuning, component testing
Engine Fuel System:
Carburetor adjustment and rebuilding, fuel pump, fuel lines, fuel tank maintenance
Engine Ignition System:
Ignition coil, spark plugs, timing, CDI unit diagnostics
Transmission:
Clutch operation, belt drive system, gearbox maintenance and repair
Drivetrain:
Axles, driveshafts, differentials, CV joints
Suspension:
Front and rear suspension components, shock absorbers, bushings, alignment
Steering:
Steering column, tie rods, steering linkage, rack and pinion (if applicable)
Brakes:
Brake caliper, master cylinder, brake lines, brake pads, brake fluid, bleeding procedures
Electrical System:
Wiring diagrams, battery, starter, alternator, lighting, ignition switch, switches
Cooling System:
Radiator, fan, coolant, thermostat, water pump
Exhaust System:
Muffler, exhaust pipes, heat shields
Frame And Bodywork:
Chassis inspection, body panel removal and installation, seat, handlebars
Accessories:
Winch, racks, lighting accessories (if applicable)
Routine Maintenance:
Oil changes, filter replacements, lubrication, pre-ride checks
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair Procedures:
Step-by-step guides for component replacement and repair
Disassembly Assembly:
Detailed instructions for taking apart and putting back together various components
Torque Specifications:
Critical torque values for fasteners and critical components
Wiring Diagrams:
Comprehensive electrical schematics for all model years and configurations
Diagnostic Charts:
Flowcharts and tables to identify and resolve problems
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and electrical diagnostics)
Engine Type 400:
4-stroke, Single Cylinder
Displacement Cc 400:
Approx. 375-400cc (varies by specific sub-model within the 400 range)
Bore Stroke 400:
Varies by specific model, e.g., 83mm x 65mm
Engine Type 500:
4-stroke, Single Cylinder
Displacement Cc 500:
Approx. 499cc (varies by specific sub-model within the 500 range)
Bore Stroke 500:
Varies by specific model, e.g., 92mm x 74mm
Horsepower Estimated:
Approx. 25-30 HP (varies by engine size and tuning)
Torque Estimated:
Approx. 28-32 ft-lbs (varies by engine size)
Carburetion:
Mikuni VM34SS (typical for 400/500 models)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity Liters:
Approx. 16.5 Liters (3.7 Gallons)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled
Type:
Automatic (PVT - Polaris Variable Transmission)
Drive System:
Shaft Drive (2WD/4WD switchable)
Gear Selection:
High, Low, Neutral, Reverse
Clutch Type:
Automatic CVT belt drive system
Atv Safety Standards:
Manufactured to meet ANSI standards for ATVs.
Braking System:
Hydraulic disc brakes (front and rear)
Selectable 4Wd:
Allows riders to choose between 2WD and 4WD for optimal traction.
Lighting:
Dual headlights, taillight/brake light
Operator Protection:
Handlebar guards, footwells with integrated guards
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first.
Air Filter Cleaning:
Every 25 hours or as needed, depending on operating conditions.
Spark Plug Replacement:
Every 100 hours or annually.
Transmission Belt Inspection:
Inspect every 50 hours for wear and damage.
Engine Oil Type:
SAE 10W-40 API SG or higher (Polaris recommends their specific synthetic blend)
Engine Oil Capacity Liters:
Approx. 1.7 Liters (1.8 Quarts)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Coolant Type:
50/50 mixture of ethylene glycol antifreeze and distilled water
Carburetor Fouling:
Can occur with infrequent use or poor fuel quality, leading to rough running.
Drive Belt Wear:
CVT belts can wear and stretch over time, affecting acceleration and performance.
Suspension Bushings:
Rubber bushings in the A-arms and other suspension components can degrade and wear.
Electrical Connector Corrosion:
Exposure to elements can lead to corrosion in electrical connectors, causing intermittent issues.
