Category:
All-Terrain Vehicle (ATV)
Target User:
Recreational riders, hunters, farmers, and utility users requiring a robust and capable ATV.
Competitors:
Competed against models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Bayou/Prairie), and Suzuki (King Quad) in the utility ATV segment.
Powertrain:
Proven Polaris 4-stroke engine technology offering reliable power and torque.
Suspension:
Independent front suspension (IFS) and a robust rear suspension system providing comfortable and capable off-road performance.
Storage:
Integrated front and rear racks for carrying gear and equipment.
Lighting:
Dual front headlights and a rear tail/brake light for visibility.
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, torque specifications, timing, and carburetor tuning for both 400cc and 500cc HO engines.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), clutch service, belt inspection/replacement, drive shafts, differentials (front and rear), and final drive maintenance.
Brakes:
Hydraulic brake system service, including brake fluid specifications, bleeding procedures, caliper overhaul, master cylinder maintenance, and brake pad/shoe replacement.
Electrical System:
Wiring diagrams, component testing, battery maintenance, charging system (stator, rectifier/regulator), ignition system troubleshooting, lighting, starter motor, and accessory circuits.
Chassis Suspension:
Frame inspection, front and rear suspension components (shocks, A-arms, bushings), steering system, wheel bearings, and hub assembly service.
Cooling System:
Radiator service, coolant specifications, fan operation, and thermostat troubleshooting.
Fuel System:
Fuel tank maintenance, fuel pump operation, fuel lines, and carburetor cleaning and adjustment specific to the 2001 models.
Scheduled Maintenance:
Detailed maintenance schedules, including oil changes, filter replacements, lubrication points, and pre-ride inspections.
Troubleshooting Diagnostics:
Comprehensive troubleshooting guides for common problems, diagnostic charts, and symptom-based repair instructions.
Rebuilds Overhauls:
Step-by-step procedures for engine, transmission, and suspension component rebuilds and overhauls.
Adjustments Calibration:
Carburetor tuning, idle speed adjustments, valve clearance checks, and clutch engagement settings.
Special Tools:
Identification and usage of special tools required for specific repair procedures.
Depth:
In-depth technical coverage suitable for professional technicians and advanced DIY mechanics, covering everything from routine maintenance to complete engine rebuilds and complex electrical diagnostics.
Engine Type 400:
4-stroke, liquid-cooled, SOHC, single-cylinder
Displacement 400:
375cc (approx.)
Engine Type 500:
4-stroke, liquid-cooled, SOHC, single-cylinder (High Output - HO)
Displacement 500:
499cc (approx.)
Horsepower 500:
Estimated 30-35 HP (varies slightly by source)
Carburetor Type:
Mikuni VM Series (typically 34mm for 400, 36mm for 500 HO)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled with fan assist
Transmission Type:
Polaris Variable Transmission (PVT) automatic with Hi/Lo range and Reverse
Drive System:
Shaft Drive, AWD (All-Wheel Drive) on demand
Clutch Type:
Centrifugal clutch (primary) and fixed sheave (secondary)
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (SAE 80W-90)
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm)
Dry Weight:
Approx. 570-600 lbs (258-272 kg)
Ground Clearance:
Approx. 10.25 inches (26 cm)
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Towing Capacity:
1500 lbs (680 kg)
Front Tire Size:
AT 25x8-12
Rear Tire Size:
AT 25x11-10
Atv Safety Certification:
Designed and manufactured to meet ANSI standards for ATVs.
Braking:
Hydraulic disc brakes, front and rear.
Throttle Limiter:
Thumb throttle with safety stop mechanism.
Rollover Protection:
N/A (ATVs are inherently open-frame vehicles; rider skill and caution are paramount).
Lighting:
Headlights, taillight, and brake light for increased visibility.
Oil Change Interval:
Every 100 hours or 1 year (whichever comes first); check manual for specific recommendations.
Air Filter Cleaning:
Inspect every 50 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Check gap every 50 hours, replace as recommended (typically around 200-300 hours or annually).
Engine Oil Type:
Polaris Synthetic 4-stroke Engine Oil or equivalent API SG/SH/SJ rated, SAE 0W-40 or 5W-50 (refer to manual for exact temp range recommendations).
Engine Oil Capacity:
Approx. 2.1 quarts (2.0 liters) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze (e.g., 50/50 mix with distilled water) with corrosion inhibitors.
Carburetor Issues:
Clogged pilot jets, vacuum leaks, and carburetor maladjustment can lead to poor running conditions. The manual provides detailed cleaning and tuning procedures.
Clutch Wear:
Drive belt wear and clutch sheave wear can affect performance. The manual details inspection and replacement of belts and clutch components.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can cause intermittent electrical issues. The manual's wiring diagrams are invaluable for troubleshooting.
Suspension Bushings:
Wear in A-arm and shock bushings can lead to clunking noises and poor handling. The manual provides replacement instructions.
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, utility, and off-road capability. The 2001 models represent an evolution of earlier Sportsman designs.
Manufacturing Location:
Primarily manufactured in Roseau, Minnesota, USA.
