Target Audience:
Dealership mechanics, professional repair shops, and experienced ATV owners performing their own maintenance and repairs.
Manual Value Proposition:
Provides essential, factory-authorized information for efficient and accurate servicing, saving time and money.
Technical Illustrations:
Contains numerous clear pictures and detailed exploded-view illustrations for visual guidance.
Organization:
Organized in a convenient PDF format with advanced search and bookmarking features.
Engine Mechanical:
Complete engine teardown and rebuild procedures, including cylinder head, pistons, crankshaft, camshaft, valve train, lubrication system, and cooling system.
Fuel System:
Carburetor adjustment and overhaul, fuel pump operation, fuel lines, fuel filter replacement, and fuel tank service.
Ignition System:
Ignition timing, spark plugs, ignition coil testing, CDI unit diagnosis, and wiring schematics.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox inspection and repair, drive shaft maintenance, CV joint service, and differential overhaul.
Suspension Steering:
Front and rear suspension component inspection, shock absorber replacement, steering linkage adjustments, wheel bearing service, and alignment procedures.
Brakes:
Brake caliper service, brake pad replacement, brake line inspection and replacement, master cylinder overhaul, and bleeding procedures.
Electrical System:
Battery testing and maintenance, starter motor operation, charging system (stator and regulator), lighting system, and comprehensive wiring diagrams.
Bodywork Chassis:
Frame inspection, body panel removal and installation, seat service, luggage rack mounting, and fender maintenance.
Cooling System:
Radiator inspection, coolant flush and refill, fan operation, thermostat testing, and hose replacement.
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, spark plug checks, valve adjustments, and lubrication points.
Troubleshooting:
Diagnostic charts and symptom-based troubleshooting guides for common performance issues, starting problems, and electrical faults.
Repair Procedures:
Step-by-step instructions for virtually all repair tasks, from minor adjustments to complete component overhauls.
Disassembly Assembly:
Exploded view illustrations clearly depicting the order of disassembly and reassembly for various components.
Specifications Data:
Torque specifications for all fasteners, clearances, fluid capacities, and performance data.
Depth Of Coverage:
Comprehensive, dealership-level technical information suitable for professional mechanics and experienced DIY enthusiasts.
Searchability:
Fully keyword searchable
Navigation:
Completely bookmarked for easy navigation
Compatibility:
Compatible with Windows, MAC, and other PDF-enabled devices.
Viewing Features:
Allows zooming, printing, and easy viewing.
Quality Description:
High-quality digital reprint, not a low-quality photocopy or scan. Clear text and sharp illustrations.
Binding:
Not applicable (digital download)
Paper Quality:
Not applicable (digital download)
Engine Configuration:
Single-cylinder (commonly referred to as 400cc and 500cc variants, likely based on a common engine block with different bore/stroke or tuning).
Displacement 400:
Approximately 375cc (varies slightly by specific model variant within the 400 designation).
Displacement 500:
Approximately 499cc (varies slightly by specific model variant within the 500 designation).
Horsepower Approx 400:
Typically in the range of 25-30 HP (exact figures depend on specific tuning and dynamometer testing).
Horsepower Approx 500:
Typically in the range of 30-35 HP (exact figures depend on specific tuning and dynamometer testing).
Carburetion:
Mikuni or Keihin carburetor, specific model and size vary by engine displacement.
Fuel Type:
Unleaded gasoline (minimum octane rating specified in manual, typically 87 or 89).
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive System:
Shaft drive with selectable 2WD/4WD and often locking front differential.
Transmission Features:
High/Low range gearing, Reverse, Park.
Belt Drive Maintenance:
Procedures for belt inspection, tension adjustment, and replacement of the CVT belt.
Length Approx:
Approx. 81-83 inches (varies slightly by model variant).
Width Approx:
Approx. 46 inches (varies slightly by model variant).
Height Approx:
Approx. 45-48 inches (varies slightly by model variant).
Dry Weight Approx:
Approx. 550-600 lbs (varies slightly by model variant).
Ground Clearance Approx:
Approx. 10-11 inches.
Rack Capacity Front Approx:
Approx. 50 lbs.
Rack Capacity Rear Approx:
Approx. 100 lbs.
Infotainment Features:
Basic instrumentation panel: speedometer, odometer, trip meter, fuel gauge, 4WD indicator, neutral indicator, oil pressure light, and engine temperature light.
Driver Assistance Features:
Selectable 2WD/4WD system with potential for locking front differential provides enhanced traction control.
Engine Oil Change:
Recommended every 100 hours or 6 months, whichever comes first.
Air Filter Cleaning:
Inspect every 25 hours, clean or replace as needed depending on operating conditions. Replace annually.
Spark Plug Replacement:
Replace every 12 months or 100 hours of operation.
Valve Lash Check:
Recommended every 200 hours or annually.
Engine Oil Type:
SAE 5W-50 Synthetic ATV oil (Polaris brand recommended, or equivalent meeting API SG/SH/SJ specifications).
Engine Oil Capacity:
Approximately 2.0 quarts (1.9 liters) with filter change. Exact capacity specified in manual.
Gearcase Oil Type:
Polaris Demand Drive Fluid for front differential; Polaris Angle Drive Fluid for rear differential (if applicable, many models use a sealed unit).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, and brake pads due to typical off-road use.
Potential Electrical Faults:
Occasional issues with voltage regulator or stator, especially after deep water submersion. Wiring harness integrity checks are important.
Manufacturer:
Polaris Industries, a long-standing American manufacturer known for ATVs and snowmobiles.
Sportsman Line Significance:
The Sportsman line is Polaris's flagship line of utility ATVs, recognized for its comfort, capability, and all-wheel-drive systems.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
