Basic Information Identification Make: Polaris Model: Sportsman Year: 2001 Model Variant: 500 H.O. Engine Displacement Cc 400: 378 Engine Displacement Cc 500: 499 Codes Chassis Code: A01 Introduction Market Position Positioning: Essential resource for owners and technicians seeking to maintain, repair, or restore the 2001 Polaris Sportsman 400/500 series ATVs. Competitive Analysis Advantage: Provides comprehensive official factory data, crucial for accurate and efficient servicing, unlike generic repair guides. Key Features Features: Complete coverage of all major systems, detailed diagnostics, high-quality illustrations and diagrams, printable format. Illustration Quality: Detailed illustrations and diagrams enhance understanding of complex procedures. Manual Details Coverage Areas Vehicle Coverage: 2001 Polaris Sportsman 400, 2001 Polaris Sportsman 500 DUSE, 2001 Polaris Sportsman 500 H.O. Page Count Estimated Page Count: High (Detailed, comprehensive coverage expected for a workshop manual) Manual Type Type: Official Workshop Service and Repair Manual Language Language: English Format Format: PDF Download Searchability: PDF format typically allows for text searching, improving efficiency in finding specific information. Support Replacement Policy: Free replacement if manual is lost, contact seller with information. Guarantee: Money Back Guarantee Manual Coverage Systems Covered Covered Systems: General Information, Maintenance, Engine, Fuel System/Carburetion, Body, Suspension, PVT System, Final Drive, Transmission, Brakes, Electrical System Wiring Diagrams: Includes specific wiring diagrams for 2001 Sportsman 400, 2001 Sportsman 500 Early, and 2001 Sportsman 500 Late models. Electrical System Detail: Covers battery, charging system, ignition system, lighting, starter motor, and all related components. Pvt System Coverage: Detailed instructions for PVT (Primary and Secondary sheave inspection, belt replacement, roller maintenance). Suspension Detail: Front and rear suspension components, including shocks, A-arms, bushings, and steering components. Procedures Included Included Procedures: Repair, Maintenance, Rebuilding, Refurbishing, Restoration, Diagnostics, Step-by-step repair instructions, Overhauls Diagnostic Procedures: Detailed diagnostic flowcharts and troubleshooting guides for various system issues. Troubleshooting Guide: Comprehensive troubleshooting section for identifying and resolving common and uncommon faults. Technical Depth Depth: Complete Official Workshop Service and Repair Manual with detailed illustrations, diagrams, wiring schematics, and specifications. Engine Rebuild Coverage: Complete engine overhaul procedures, including torque specifications, clearances, and component replacement. Manual Specifications File Format Format: PDF Print Quality Printability: All pages are printable. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type 400: 4-stroke, liquid-cooled, SOHC, 2-valve, 378cc Engine Type 500: 4-stroke, liquid-cooled, SOHC, 4-valve, 499cc Engine Layout 400: Single Cylinder, 4-stroke Engine Layout 500: Single Cylinder, 4-stroke Performance Bore Stroke 400: 80mm x 75mm Bore Stroke 500: 92mm x 75mm Cooling System: Liquid-cooled Fuel System Carburetion 400: Mikuni BSR42 Carburetion 500: Mikuni BSR40 (DUSE), Mikuni BSR42 (H.O.) Fuel Type: Unleaded gasoline Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Optional Gear Selection: High, Low, Neutral, Reverse Features Drive System: Shaft Drive (AWD - Automatic All-Wheel Drive) Final Drive Type: Shaft Drive with limited-slip differential Clutch Type: Automatic Clutch (in PVT) Dimensions Exterior Wheelbase: Approximately 50.5 inches (1283 mm) Weights Dry Weight 400: Approximately 650 lbs (295 kg) Dry Weight 500: Approximately 650-655 lbs (295-297 kg) Safety Features Ratings Safety Features: Integrated braking system, throttle limiter (adjustable), park brake. Active Features Active Safety: AWD system provides enhanced traction and stability. Technology Features Infotainment Infotainment System: N/A (Basic ATV design) Driver Assistance Assistance Features: Automatic All-Wheel Drive (AWD) system engages front wheels when rear wheels slip. Connectivity Connectivity Options: N/A Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hour intervals, typically every 100 hours or annually. Air Filter Maintenance: Inspect and clean/replace at specified intervals or as needed based on operating conditions. Spark Plug Replacement: Replace at specified intervals or as needed. Specific gap setting provided in manual. Brake Fluid Check: Check fluid level and condition regularly, flush and replace as per schedule. Fluid Specifications Engine Oil Type: SAE 20W-50 API SG or higher. Polaris recommends their specific formulations. Coolant Type: Ethylene glycol-based antifreeze (50/50 mix with distilled water) Final Drive Fluid: SAE 80W-90 GL-5 Gear Oil Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 80W-90 GL-4 gearcase lubricant Known Issues Common Wear Items: PVT belt wear, spark plugs, air filters, brake pads, suspension bushings. Potential Failures: Carburetor adjustments, occasional stator issues, water pump seal leaks if not maintained. Specific Maintenance Points: Grease points, bearing checks, exhaust system maintenance. Vehicle History Brand Heritage Heritage: Polaris Industries, Inc. has a long-standing reputation for innovation and quality in the powersports industry, particularly with its ATV lines. Model Evolution Evolution: The Sportsman series has been a cornerstone of Polaris's ATV offerings, known for its comfort, utility, and capability. The 2001 models represent a refinement of established platforms. Production Production Era: Early 2000s