Market Segment:
Mid-size utility ATV
Target User:
Recreational riders, hunters, farmers, utility users
Key Competitors:
Honda FourTrax, Yamaha Grizzly, Can-Am Outlander
Powertrain Layout:
4x4 with AWD
Suspension Type:
Independent Front Suspension (IFS), IRS (Independent Rear Suspension) on some variants
Cargo Capacity:
Front and rear racks for substantial cargo hauling
Towing Capacity:
Significant towing capability
Engine Mechanical:
Engine disassembly, assembly, inspection, overhaul
Fuel System:
Carburetor tuning, fuel pump, fuel filter, fuel lines
Ignition System:
Spark plugs, ignition coil, CDI unit, timing
Cooling System:
Radiator, fan, coolant, thermostat, water pump
Exhaust System:
Muffler, exhaust pipe, gaskets
Transmission Drivetrain:
Gearbox, drive shafts, differentials, clutches, belt drive system
Suspension System:
Front and rear suspension components, shock absorbers, A-arms, bushings
Steering System:
Handlebars, tie rods, steering knuckles, steering column
Braking System:
Hydraulic brake system, calipers, master cylinders, brake pads, rotors, lines
Electrical System:
Battery, charging system, starter, lighting, wiring diagrams, switches
Body Chassis:
Frame, body panels, seats, racks, fenders
Wheels Tires:
Wheel mounting, tire specifications
Routine Maintenance:
Oil changes, filter replacements, lubrication, brake adjustments
Troubleshooting:
Diagnostic procedures for common problems, error codes
Repair Procedures:
Step-by-step instructions for component replacement and repair
Overhaul Rebuild:
Detailed instructions for complete engine and transmission rebuilds
Torque Specifications:
Essential torque values for critical fasteners
Wiring Diagrams:
Comprehensive electrical system schematics
Depth Level:
Comprehensive factory-level repair and diagnostic information
Engine Displacement:
499cc
Engine Configuration:
Single-cylinder, liquid-cooled, SOHC, 4-valve
Bore X Stroke:
92 mm x 75.5 mm
Horsepower Approx:
30-35 HP (estimated)
Torque Approx:
30-35 lb-ft (estimated)
Fuel Delivery:
Carburetor (Mikuni BSR42)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Fuel Tank Capacity:
4.0 US gal (15.1 L)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand All-Wheel Drive (AWD)
Gear Reduction:
High and Low range
Atv Safety Standards:
Adherence to ANSI/SVIA safety standards
Braking System Type:
Hydraulic disc brakes, front and rear
Engine Braking:
Engine braking assist through PVT system
Handlebars:
Ergonomic handgrips and controls
Lighting:
Dual headlights, taillight/brake light
Tire Type:
ATV-specific, knobby tread pattern for traction
Engine Oil Change:
Every 100 hours or annually
Oil Filter Change:
Every 100 hours or annually
Air Filter Inspection:
Every 25 hours or monthly
Spark Plug Replacement:
Every 100 hours or annually
Drive Belt Inspection:
Every 100 hours or annually
Engine Oil Type:
SAE 20W-50, API SG or higher (Polaris recommends specific oil)
Engine Oil Capacity:
Approx. 2.2 US quarts (2.1 L) with filter
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Transmission Fluid Type:
SAE 20W-50, API SG or higher (Polaris recommended)
Gearcase Fluid Type:
SAE 80W-90 GL-4 Gear Oil
Common Wear Items:
Drive belt, bushings, tie rod ends, brake pads
Potential Electrical Issues:
Wiring harness fatigue, stator/rectifier failure (less common on this model)
Fuel System Considerations:
Carburetor jetting can be sensitive to altitude and modifications
Brand History:
Polaris Industries is a long-standing manufacturer of recreational and utility vehicles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort and capability.
Production Era:
The Sportsman 500 has been in continuous production with various updates since the mid-1990s.
Key Innovations 500 Series:
Introduction of Independent Rear Suspension (IRS) on some models, enhanced AWD systems.