Segment:
Polaris Sportsman 500 6x6 is positioned as a versatile and capable utility ATV, known for its 6-wheel drive capability, suitable for demanding work and recreational off-road activities.
Competitors:
Competes with other utility ATVs from brands like Can-Am (Outlander 6x6), Arctic Cat (Prowler XTZ), and John Deere, offering similar payload and towing capabilities.
Unique Selling Points:
The 6x6 drivetrain provides enhanced traction and stability in challenging terrain, making it ideal for hauling, towing, and navigating difficult landscapes.
Primary Benefit:
This manual is essential for owners and technicians to perform proper maintenance, diagnostics, and repairs, ensuring the longevity and optimal performance of the ATV.
Target Audience:
Owners, DIY enthusiasts, mechanics, and repair shops specializing in ATVs.
General:
Includes general information, specifications, and model identification.
Maintenance:
Covers routine maintenance, lubrication charts, and periodic maintenance schedules.
Engine:
Detailed coverage of engine disassembly, assembly, inspection, and tuning. Includes internal components like pistons, crankshaft, camshaft, valves, and cooling system.
Carburetion:
In-depth information on carburetor systems, including disassembly, adjustment (pilot screw, choke), float height, fuel level testing, and troubleshooting.
Clutching:
Covers Primary Variable Transmission (PVT) systems, including disassembly, assembly, maintenance, operation, and troubleshooting. Includes drive and driven clutch service.
Final Drive:
Details on front and rear axle assemblies, gearcases, AWD armature plates, magnetic coils, CV joints, and associated seals and bearings.
Body And Steering:
Includes information on body panel removal, steering assembly, tie rods, front struts, and suspension components.
Transmission:
Comprehensive coverage of transmission systems, including removal, installation, disassembly, assembly, and linkage adjustments.
Brakes:
Detailed procedures for brake system maintenance, including bleeding, fluid changes, caliper service (disassembly, assembly, inspection, removal/installation), brake disc inspection, and pad replacement.
Electrical:
Extensive electrical system coverage, including battery service, charging system tests, ignition system, CDI output tests, starter system, lighting (headlights, taillights), instrument clusters, and diagnostic modes for both 2004 and 2005 models.
Maintenance Procedures:
Includes air filter service, battery maintenance, brake bleeding/fluid change, carburetor float bowl draining, chain adjustment, choke adjustment, coolant level inspection, drive belt inspection, fuel filter maintenance, idle speed adjustment, oil changes, spark plug maintenance, steering maintenance, throttle cable adjustment, tire pressure, valve clearance adjustments.
Repair Procedures:
Covers engine component replacement (pistons, rings, valves, camshaft, crankshaft), clutch service, brake caliper repair, electrical component testing and replacement (starter motor, stator, ignition components), suspension component replacement (A-arms, struts, ball joints), drive axle repair (CV joints, seals), and transmission overhaul.
Troubleshooting:
Provides dedicated troubleshooting sections for engine, cooling system, fuel system/carburetor, ignition system, brakes, starter system, and speedometer/instrument cluster issues specific to 2004 and 2005 models.
Diagnostic Procedures:
Details diagnostic modes for 2004 and 2005 models, including service interval programming, high engine coolant temperature indicators, battery voltage warnings, and ETC (Electronic Throttle Control) switch testing.
Depth:
Comprehensive, covering everything from basic pre-ride inspections and fluid changes to complete engine rebuilds, transmission overhauls, and detailed electrical system diagnostics.
Type:
4-stroke, liquid-cooled, single-cylinder
Displacement:
Approx. 499cc (based on common Polaris 500 engines of the era)
Bore X Stroke:
Refer to specific model year specifications within the manual (typically around 92.1 mm x 76 mm)
Compression Ratio:
Refer to specific model year specifications within the manual (typically around 9.0:1)
Horsepower:
Approximately 28-34 HP (depending on specific model year and tuning, refer to manual for exact specs)
Torque:
Refer to specific model year specifications within the manual for exact torque figures.
Carburetor Model:
Likely a Mikuni BST34 or similar downdraft carburetor, as indicated by exploded views.
Fuel Type:
Unleaded gasoline (minimum octane rating specified in manual)
Fuel Delivery:
Fuel pump and carburetor
Oil Type:
Refer to manual for specific SAE viscosity grade and API service classification (e.g., SAE 20W-50 or similar).
Oil Capacity:
Refer to manual for exact oil capacity (typically around 2.5 - 3 quarts).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (specified mixture ratio and type in manual).
Oil Change:
Typically every 100 hours or annually, whichever comes first. (Refer to manual for precise intervals).
Air Filter Cleaning:
Inspect and clean every 20-30 hours, replace as needed. (Refer to manual for precise intervals).
Spark Plug Replacement:
Typically every 100 hours or annually. (Refer to manual for specific plug type and gap).
Valve Adjustment:
Check and adjust every 100 hours. (Refer to manual for specific procedures and clearances).
Belt Inspection:
Inspect drive belt for wear and damage every 50 hours. Replace as needed.
Engine Oil:
Refer to manual for exact SAE viscosity grade and API classification. Common specifications include SAE 20W-50.
Coolant:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, as specified in the manual.
Gearcase Lubricant:
Refer to manual for specific gear oil type and viscosity for front, rear, and potentially center gearcases.
Drive Belt Wear:
Regular inspection and replacement are crucial to prevent breakdown.
Carburetor Issues:
Can be prone to clogging from debris or stale fuel, requiring cleaning and adjustment.
Electrical Connections:
Corrosion or loose connections can lead to intermittent electrical issues.
Suspension Wear:
Bushings and ball joints in the suspension may wear over time with heavy use.
