DIY enthusiasts and experienced professional mechanics seeking comprehensive repair and maintenance information.
Competitive Analysis
Value Proposition:
Provides an inexpensive way to maintain and repair ATVs, empowering owners to perform tasks themselves and save on labor costs.
Key Features
Content Quality:
100% complete and intact, no missing or corrupt pages, detailed illustrations, exploded diagrams, drawings, and photos.
Delivery Method:
Instant download, no shipping costs or waiting time.
📋 Manual Details
Coverage Areas
Covered Models:
Polaris Sportsman 500, Polaris Xplorer 500, Polaris Worker 500, and various special editions including RSE, DUSE, H.O., and Remington Special Editions across the specified model years.
Page Count
Total Pages:
504
Manual Type
Type:
Official Service and Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine top end, engine lower end, fuel system (carburetion), cooling systems, clutch/drive belt system, transmission, final drive.
Chassis And Body:
Front suspension and steering, rear suspension, brakes, body, wiring diagrams.
Procedures Included
Repair And Rebuild:
Complete tear down and rebuild of all major components, detailed step-by-step repair procedures.
Maintenance And Tuneup:
Lubrication, maintenance schedules, tune-up procedures, diagnostic and repair procedures.
Troubleshooting:
Comprehensive troubleshooting guides for common and complex issues.
Technical Depth
Depth:
Extremely detailed, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printable:
Fully printable pages
Binding Type
Digital Binding:
Bookmarked and searchable for easy navigation
Paper Type
Digital Paper Simulation:
Simulates high-quality, professional paper documentation with detailed illustrations and diagrams.
Compatibility
Software Requirements:
Adobe PDF Reader, WinZip (for extraction if compressed)
Operating Systems:
All versions of Windows and Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (typical for this era and model range).
Performance
Displacement:
499cc (for 500cc models). 400cc for 400cc models.
Bore X Stroke:
Specifics will be detailed in the manual, typically around 93.2 mm x 73.6 mm for 500cc models.
Fuel System
Fuel Delivery:
Carbureted (specific carburetor model and settings detailed in manual, e.g., Mikuni BSR42).
Fuel Type:
Unleaded gasoline (regular octane, typically 87).
Engine Components
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic advance.
Cooling System:
Liquid-cooled with fan assist.
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse.
Features
Drive System:
Shaft drive to front and rear differentials, On-Demand AWD (All-Wheel Drive) typically engaged electronically.
Clutch System:
Automatic centrifugal clutch and drive/driven pulleys for CVT operation.
📐 Dimensions
Exterior
Length:
Varies slightly by year and model, typically around 82-85 inches.
Width:
Typically around 46-48 inches.
Height:
Typically around 46-48 inches.
Weights
Dry Weight:
Varies by model, generally in the 600-700 lbs range.
Cargo Capacity Rack Front:
Typically rated around 90 lbs.
Cargo Capacity Rack Rear:
Typically rated around 180 lbs.
Towing Capacity:
Typically rated around 1,500 lbs.
Fuel Capacity:
Typically 3.2-3.7 gallons (including reserve).
🛡️ Safety Features
Ratings
Atv Safety Standards:
Designed to meet or exceed industry safety standards for ATVs of its era.
Active Features
Braking System:
Hydraulic disc brakes on all wheels (typically 3 or 4 wheels depending on configuration and year), hand and foot brake controls.
Lighting:
Headlights, taillight, brake light.
Passive Features
Rollover Protection:
Standard ATV design principles, rider responsibility for safe operation.
Restraint System:
No occupant restraint system (seatbelt). Riders are required to wear helmets and appropriate protective gear.
💡 Technology Features
Infotainment
Display Features:
Basic LCD instrumentation panel displaying speed, odometer, trip meter, 4WD indicator, etc. (specifics vary by year).
Factory pre-wired for accessories, though not considered modern 'connectivity'.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 100 hours or annually (details in manual).
Air Filter Cleaning:
Recommended at frequent intervals, especially in dusty conditions (details in manual).
Spark Plug Replacement:
Recommended at specified hours or annually (details in manual).
Fluid Specifications
Engine Oil Type:
Polaris specifically recommends its own brand of synthetic ATV engine oil (e.g., 0W-40 or 10W-40, check manual for exact specification).
Gearcase Oil Type:
Polaris Demand Drive Fluid for front differential, Polaris Gearcase Lubricant for rear differential (specific grades and capacities in manual).
Coolant Type:
Ethylene glycol-based antifreeze mixture (typically 50/50 with distilled water, check manual for exact type).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific requirement).
Known Issues
Common Wear Items:
CV boots, tie rod ends, suspension bushings, wheel bearings, starter motor, battery.
Engine Performance:
Carburetor tuning, fuel system cleaning, clutch wear can affect performance. High Output (H.O.) models introduced later offer improved power.
Electrical System:
Stator failures, voltage regulator issues, and wiring harness corrosion can occur over time.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Polaris Industries Inc., founded in Minnesota, USA, known for its history in snowmobiles and expanding into ATVs.
Model Evolution
Sportsman Lineage:
The Sportsman line has been a flagship series for Polaris, emphasizing comfort, utility, and reliable performance for trail riding and work.
Production
Manufacturing Location:
Primarily manufactured in the United States by Polaris.
Market Introduction:
The Sportsman 500 was introduced as a significant advancement in ATV technology and comfort for its time.
🏆 Awards & Recognition
Recognitions
Industry Standing:
The Polaris Sportsman line has consistently been a top seller and highly regarded in the ATV market for its balance of features and performance.
Ratings
Consumer Perception:
Generally positive consumer reviews for durability, comfort, and utility, with specific model years and engine variations receiving higher accolades (e.g., H.O. models).