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Introduction
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Market Position
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Segment:
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Utility ATV (All Terrain Vehicle)
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Target User:
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Professional users, landowners, hunters, recreational riders requiring robust performance and utility
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Competitive Analysis
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Competitors:
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Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou, Suzuki King Quad
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Key Features
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Utility Focus:
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Emphasis on work capability, towing, hauling, and reliable operation in diverse terrains
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Durability:
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Designed for rugged use and extended operational life
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Manual Coverage
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Systems Covered
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Powertrain:
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Engine, Transmission, Drive Systems (AWD/2WD), Differentials, Drive Shafts, CV Joints
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Chassis:
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Frame, Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Wheels, Tires
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Electrical:
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Ignition System, Charging System (Stator, Rectifier/Regulator, Battery), Starting System (Starter Motor, Solenoid), Lighting, Instruments, Wiring Diagrams, Switches, Controls
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Fuel System:
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Carburetor(s) (Maintenance, Adjustment, Rebuild), Fuel Pump, Fuel Lines, Fuel Tank
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Cooling System:
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Radiator, Fan, Hoses, Thermostat, Coolant
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Exhaust System:
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Exhaust Pipes, Muffler, Heat Shields
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Body And Trim:
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Body Panels, Fenders, Racks, Seat, Handlebars, Decals
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Procedures Included
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Maintenance:
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Regular scheduled maintenance, oil changes, filter replacements, lubrication points, battery care, tire pressure checks
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Repair:
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Engine overhaul, transmission repair, carburetor rebuild, brake system service, suspension component replacement, electrical component troubleshooting and repair
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Troubleshooting:
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Diagnostic charts for common problems (starting issues, poor performance, electrical faults, etc.)
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Specifications:
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Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters
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Diagrams:
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Detailed exploded views, wiring diagrams, service illustrations
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Technical Depth
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Depth:
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Comprehensive (from basic maintenance to complete engine and component rebuilds)
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Engine Specifications
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Primary Engine
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Engine Type 400:
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4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder
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Engine Type 500:
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4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder
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Displacement
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Displacement 400:
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Approximately 375cc - 400cc (exact varies by specific sub-model/year)
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Displacement 500:
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Approximately 499cc - 500cc (exact varies by specific sub-model/year)
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Performance
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Horsepower 400:
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Estimated 20-25 HP (varies by year/tuning)
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Horsepower 500:
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Estimated 28-32 HP (varies by year/tuning)
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Torque 400:
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Estimated 22-25 lb-ft (varies by year/tuning)
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Torque 500:
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Estimated 28-32 lb-ft (varies by year/tuning)
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Fuel System
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Carburetor Type:
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Mikuni or Keihin Single Carburetor (specific model dependent)
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Fuel Type:
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Unleaded Gasoline
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Lubrication
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Oil Type:
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SAE 20W-50 or 10W-40 Motorcycle/ATV Oil (refer to manual for exact specification)
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Cooling System
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Coolant Type:
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Ethylene Glycol-based Antifreeze (50/50 mix with distilled water recommended)
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Dimensions
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Exterior
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Length:
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Approx. 80-85 inches (203-216 cm)
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Width:
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Approx. 45-48 inches (114-122 cm)
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Height:
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Approx. 46-48 inches (117-122 cm)
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Weights
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Dry Weight:
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Approx. 550-600 lbs (249-272 kg)
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Ground Clearance:
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Approx. 8-11 inches (20-28 cm)
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Cargo
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Rack Capacity Front:
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Approx. 90 lbs (40 kg)
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Rack Capacity Rear:
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Approx. 200 lbs (90 kg)
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Towing Capacity:
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Approx. 1,225 - 1,500 lbs (556 - 680 kg)
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Tires
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Front Tire Size:
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25x8-12 or 26x8-12 (typical)
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Rear Tire Size:
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25x11-12 or 26x11-12 (typical)
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Tire Pressure Front:
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Typically 5-7 PSI (refer to manual for exact specs)
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Tire Pressure Rear:
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Typically 5-7 PSI (refer to manual for exact specs)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 100 hours or annually (whichever comes first)
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Air Filter Cleaning:
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Inspect every 20 hours, clean or replace as needed. Service more frequently in dusty conditions.
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Spark Plug Replacement:
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Recommended every 100-200 hours or annually.
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Drive Belt Inspection:
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Inspect regularly for wear and damage, replace as needed (typical replacement interval 1000-2000 hours, but inspection is key).
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Fluid Specifications
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Engine Oil Capacity:
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Approximately 2.0 - 2.5 quarts (1.9 - 2.4 liters) - refer to manual for exact capacity
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Coolant Capacity:
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Approximately 1.5 - 2.0 quarts (1.4 - 1.9 liters) - refer to manual for exact capacity
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Brake Fluid Type:
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DOT 3 or DOT 4 Hydraulic Brake Fluid
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Known Issues
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Cvt Belt Wear:
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CVT belt wear or slippage can occur with heavy use or improper maintenance.
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Carburetor Tuning:
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Carburetors may require periodic cleaning and tuning, especially if the vehicle sits for extended periods.
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Electrical Connections:
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Corrosion or looseness in electrical connections can lead to intermittent issues.
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Vehicle History
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Brand Heritage
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Polar Heritage:
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Polaris has a long history of producing off-road vehicles, including ATVs, snowmobiles, and UTVs, known for innovation and ruggedness.
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Model Evolution
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Sportsman Lineage:
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The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from basic utility models to feature-rich recreational and work-oriented machines.
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Xplorer Worker Positioning:
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These models combined the ruggedness of the Explorer series with the 'Worker' designation emphasizing enhanced utility and towing capabilities, targeting agricultural, ranching, and heavy-duty recreational use.
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Production
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Manufacturing Location:
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Primarily manufactured in the United States by Polaris Industries.
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