Coverage Areas:
General Information, Maintenance, Engine, Carburetion, Body and Steering, Clutching, Final Drive, Transmission, Brakes, Electrical
Compatible Operating Systems:
All Versions of Windows & Mac
Required Software:
Adobe PDF Reader
Engine System:
Comprehensive engine overhaul, component diagnosis, timing, cooling system, lubrication.
Fuel System:
Carburetor tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel tank maintenance.
Drivetrain System:
Clutch operation, belt inspection/replacement, primary/secondary clutch service, gearcase maintenance, final drive assembly, driveshaft, CV joints.
Transmission System:
Transmission disassembly, reassembly, gear selection, troubleshooting common issues.
Brake System:
Brake caliper service, hydraulic system bleeding, brake pad replacement, rotor inspection.
Electrical System:
Wiring diagrams, component testing (stator, starter, battery, lights), ignition system troubleshooting.
Chassis And Body:
Frame inspection, body panel removal/installation, steering system components, suspension adjustment.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, valve adjustments.
Troubleshooting Guides:
Diagnostic flowcharts for common performance, starting, and operational issues.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds.
Engine Type:
4-Stroke, 2-Cylinder, SOHC
Engine Type:
4-Stroke, 2-Cylinder, SOHC
Horsepower Estimate:
Approx. 26-30 HP (Varies by specific sub-model and tuning)
Torque Estimate:
Approx. 25-30 ft-lbs (Varies)
Carburetion Type:
Keihin Carburetor (Specific model numbers likely detailed in manual)
Oil Type Spec:
Likely SAE 10W-40 or 20W-50, API SG or higher (Refer to manual for exact specification)
Cooling Method:
Liquid-Cooled
Clutch Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Transmission Modes:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive with On-Demand AWD (All-Wheel Drive) and 2WD
Gearcase Oil Type:
Likely SAE 80W-90 Gear Oil (Refer to manual for exact specification and capacity)
Length Approx:
Approx. 81 inches (2057 mm)
Width Approx:
Approx. 46 inches (1168 mm)
Height Approx:
Approx. 47 inches (1194 mm)
Dry Weight Approx:
Approx. 620 lbs (281 kg)
Towing Capacity:
Often rated at 1,500 lbs (680 kg) (Verify in manual)
Cargo Capacity Rear Rack:
Typically around 100 lbs (45 kg)
Cargo Capacity Front Rack:
Typically around 50 lbs (23 kg)
Atv Safety Standards:
Designed to meet or exceed industry safety standards for ATVs (e.g., ANSI).
Braking System:
Hydraulic disc brakes front and rear.
All Wheel Drive:
On-Demand All-Wheel Drive provides enhanced traction in challenging terrain.
Handlebar Protection:
Handguards (often standard or optional) for hand protection.
Ergonomics:
Designed for rider comfort and control.
Display Features:
Digital odometer, trip meter, clock, engine hour meter (depending on trim).
AWD System:
On-Demand AWD provides automatic engagement of front wheels when slippage is detected.
Lighting:
Dual headlights, tail/brake light, often a DC outlet for charging accessories.
Engine Oil Change:
Every 100 hours or annually (Refer to manual for specific recommendation).
Air Filter Cleaning:
Regular inspection and cleaning, typically every 20-40 hours or as needed in dusty conditions.
Spark Plug Replacement:
Recommended at intervals of 1,000-1,500 hours or as indicated by wear.
Clutch Belt Inspection:
Inspect every 50 hours for wear and damage; replacement as needed.
Coolant Type:
Ethylene Glycol-based antifreeze, 50/50 mix with distilled water (Refer to manual for exact specification).
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid (Refer to manual for exact specification).
Common Wear Items:
Clutch belt, wheel bearings, ball joints, tie rod ends, spark plugs, air filters.
Potential Electrical Issues:
Stator failure, starter solenoid issues (common in many ATVs of this era).
Cooling System Maintenance:
Regular radiator and coolant checks for proper function and cleanliness are crucial.
Polaris History:
Polaris has a long history of manufacturing off-road vehicles, known for innovation in the ATV market.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, established for its versatility and comfort.
Manufacturing Location:
Typically manufactured in the USA.
