Target User:
DIY mechanics, ATV enthusiasts, service technicians
Value Proposition:
Provides comprehensive, professional repair information for cost-effective maintenance and repair.
Competitor Manuals:
Contrasts with generic online guides by offering in-depth, OEM-level detail.
Detail Level:
"The real deal" - implies authoritative and complete repair data.
Visual Aid Quality:
Emphasis on high-quality, detailed pictures and diagrams for clarity.
Engine Mechanical:
Top-end overhaul, piston, rings, cylinder, valve train, crankshaft, connecting rod, seals, gaskets
Engine Management:
Fuel injection system, ignition system, sensors, ECU diagnosis, timing
Transmission:
PVT (Polaris Variable Transmission) system, clutch maintenance (primary and secondary), belt inspection/replacement, gearcase lubrication, shifting mechanism
Drivetrain:
All-Wheel Drive (AWD) system, front differential, rear differential, driveshafts, CV joints, universal joints
Suspension:
Front and rear suspension geometry, shock absorber adjustment/replacement, control arm bushings, ball joints, steering components
Brakes:
Hydraulic brake system, caliper maintenance, brake pad replacement, rotor inspection, master cylinder, brake fluid flushing/bleeding
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, wiring diagrams, fuses, relays, ignition switch
Cooling System:
Radiator, fan, coolant, thermostat, hoses, water pump
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, injectors (if applicable), throttle body
Exhaust System:
Muffler, pipes, heat shields, gaskets
Body And Chassis:
Frame inspection, body panels, seat, handlebars, racks, fenders
Routine Maintenance:
Oil changes, filter replacements, lubrication points, spark plug checks/replacement, tire pressure checks
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation (if applicable), electrical system diagnostics
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilding
Component Disassembly Assembly:
Detailed step-by-step instructions for removing, inspecting, repairing, and reinstalling all major components
Electrical Diagnostics:
Wiring diagram interpretation, voltage/resistance testing, component testing
Depth Of Coverage:
Comprehensive from basic checks to full engine and transmission rebuilds
Diagrams Illustrations:
Tons of detailed pictures and diagrams included
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values
Engine Type 400:
4-stroke, SOHC, 2-valve, liquid-cooled, single-cylinder
Engine Type 500:
4-stroke, SOHC, 2-valve, liquid-cooled, single-cylinder
Bore X Stroke 400:
83 mm x 75 mm (approx.)
Bore X Stroke 500:
94 mm x 71.5 mm (approx.)
Displacement 400:
375cc (approx.)
Displacement 500:
499cc (approx.)
Horsepower 400:
Approx. 26-28 HP (est.)
Horsepower 500:
Approx. 30-34 HP (est.)
Torque 400:
Approx. 26-28 lb-ft (est.)
Torque 500:
Approx. 29-33 lb-ft (est.)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 Octane Recommended)
Ignition Type:
CDI (Capacitor Discharge Ignition) with electronic advance
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first)
Air Filter Cleaning:
Every 25 hours or as needed in dusty conditions
Spark Plug Inspection:
Every 100 hours or 12 months
Transmission Oil Change:
Every 200 hours or 12 months
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris recommends their own branded oil, but other compatible synthetics are suitable)
Engine Oil Capacity:
Approx. 2.1 quarts (2.0 liters) with filter change
Transmission Fluid Type:
Polaris Demand Drive Plus (or SAE 75W-90 Synthetic Gearcase Lubricant)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Pvtsystemwear:
Variable transmission belt wear and clutch sheave issues can occur with heavy use.
Efi Sensor Issues:
Occasional issues with throttle position sensors (TPS) or other EFI sensors can cause performance problems.
Suspension Bushings:
Control arm and sway bar bushings can wear over time, leading to play and knocking sounds.
Electrical Connections:
Corrosion or loose connections in electrical connectors can lead to intermittent faults.
