Model:
Sportsman 400 HO, Sportsman 400 HO Touring, Sportsman 500 HO, Sportsman 500 HO Forest Tractor, Sportsman 500 EFI
Model Variants:
400 HO, 400 HO Touring, 500 HO, 500 HO Forest Tractor, 500 EFI
Product Type:
Service Repair Manual
Positioning:
The Polaris Sportsman line is a dominant force in the utility ATV market, known for its ruggedness, versatility, and rider comfort. This manual targets owners and technicians who require in-depth knowledge to maintain and repair these popular machines.
Competitors:
This manual covers models that compete with offerings from brands like Can-Am (Outlander), Yamaha (Grizzly), Kawasaki (Brute Force), and Suzuki (KingQuad) in the mid-to-large displacement utility ATV segment.
Manual Benefits:
Provides factory-level repair information, essential for accurate diagnostics, efficient repairs, and proper maintenance, ultimately saving time and money compared to guesswork or incomplete online resources.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, transmission, driveline, final drive.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic, parking), body panels, racks.
Electrical:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, wiring diagrams, electronic control modules (ECMs/ECUs), sensors.
Accessories & Other:
Winch operation (if applicable), accessories installation, fluid capacities and specifications, lubrication points.
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, lubrication, valve clearance checks.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common problem diagnosis and solutions.
Repair & Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems.
Component Specific Procedures:
Engine rebuild procedures, transmission overhaul, carburetor/fuel injection adjustment and cleaning, brake caliper servicing, suspension component replacement.
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY technicians. Covers everything from basic fluid checks to complete engine and transmission rebuilds.
400 Ho Engine:
Typically a 375cc, liquid-cooled, 4-stroke engine. Exact horsepower and torque figures vary slightly by year but generally around 25-30 HP.
500 Ho Engine:
Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine. Horsepower typically in the range of 30-36 HP, with torque figures around 27-30 lb-ft.
500 Efi Engine:
Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine with Electronic Fuel Injection (EFI). Similar performance to the carbureted 500 HO but with improved throttle response and fuel efficiency.
Bore Stroke 400:
Approx. 82mm x 71.5mm (varies)
Bore Stroke 500:
Approx. 83mm x 92mm (varies)
Fuel Delivery 400:
Carbureted (likely Mikuni BSR series, e.g., BSR34/36)
Fuel Delivery 500 Efi:
Electronic Fuel Injection (EFI) with throttle body and fuel pump
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled with fan assist
Engine Oil Type:
Typically SAE 5W-50 Synthetic or a high-quality ATV specific oil meeting Polaris standards (e.g., PS-4).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse.
Optional Transmissions:
N/A (CVT is standard for all listed models)
Clutch System:
Primary and secondary clutch system for automatic gear changes.
Transmission Fluid Type:
Typically Polaris AGL Synthetic Gearcase Oil or equivalent. Check manual for specific part numbers and capacities.
Length:
Approximately 83 inches for standard models, longer for Touring variants (e.g., 85-90 inches).
Width:
Approximately 46 inches.
Height:
Approximately 45 inches.
Dry Weight:
Ranging from approximately 600 lbs (400 HO) to 700+ lbs (500 HO Touring).
Ground Clearance:
Typically around 10.25 inches.
Front Rack Capacity:
Typically 100 lbs.
Rear Rack Capacity:
Typically 200 lbs.
Towing Capacity:
Typically 1500 lbs (receiver hitch rated).
Payload Capacity:
Typically 250-300 lbs.
Atv Safety Considerations:
ATVs are not street legal. Operators must wear helmets and protective gear. Operate responsibly and be aware of terrain.
Braking System:
Hydraulically actuated disc brakes on all wheels. Single-lever front braking, foot-actuated rear braking. Parking brake on rear caliper.
Traction Control:
Standard AWD (All-Wheel Drive) system with Automatic Decoupling (ADC - Automatic Drive Control), which engages front drive when rear wheels slip.
Lighting:
Dual 50W headlights, dual taillight/brake lights.
Operator Safety:
Anti-kickback steering mechanism, handlebar grips, throttle limiter (adjustable).
Infotainment Systems:
Minimal. Primarily focused on functionality and utility. May include basic LCD instrumentation displaying speed, RPM, fuel level, odometer, trip meter, AWD indicator, and gear position.
Assistance Features:
Automatic AWD engagement, engine braking via CVT deceleration.
Connectivity Options:
N/A
Engine Oil Change:
Typically every 100 hours or 12 months, whichever comes first. Check manual for specific recommendations.
Air Filter Cleaning:
Every 25 hours or more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or 12 months.
Valve Clearance Check:
Typically every 100 hours or 24 months.
Transmission Fluid Change:
Typically every 100 hours or 12 months.
Engine Oil Capacity 400:
Approx. 2.0 L (with filter change).
Engine Oil Capacity 500:
Approx. 2.2 L (with filter change).
Gearcase Oil Capacity:
Approx. 0.5 L (check manual for specific fill level).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically 50/50 mix with distilled water.
Common Problems:
CVT belt wear/slipping, occasional charging system issues (rectifier failure), throttle cable adjustment, suspension wear on high-mileage units. EFI models may require occasional injector cleaning.
Polaris Atv History:
Polaris is a pioneering manufacturer in the ATV industry, credited with developing many key features and popularizing the sport-utility ATV segment. They have a long history of innovation and building durable off-road vehicles.
Sportsman Line Evolution:
The Sportsman line has been a cornerstone of Polaris' ATV offerings for decades. The 400 and 500 models represent mid-range workhorses known for their reliability and capability, evolving with engine updates, suspension improvements, and the introduction of EFI.
Production Period:
These specific models (400 HO, 500 HO, 500 EFI) were prominent in Polaris' lineup during the late 2000s and early 2010s, with continuous updates and variations.
