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Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 H.O. / 500 DUSE / 500 H.O. DUSE / 500 H.O. RSE Year: 2001 Introduction Market Position Market Position: The...

Type: Atv

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Sku: 43710

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Description

Basic Information
Identification
Make:	Polaris
Model:	Sportsman 400 / 500 H.O. / 500 DUSE / 500 H.O. DUSE / 500 H.O. RSE
Year:	2001

Introduction
Market Position
Market Position:	The 2001 Polaris Sportsman series represented Polaris's commitment to producing versatile and capable All-Terrain Vehicles (ATVs) for recreational and utility use. These models were positioned as rugged, reliable, and feature-rich options within the competitive ATV market.
Competitive Analysis
Competitive Analysis:	Competed against other major ATV manufacturers like Yamaha (Kodiak, Wolverine), Honda (FourTrax), Suzuki (King Quad), and Kawasaki (Prairie). The Sportsman series aimed to differentiate itself through its independent rear suspension (IRS) on certain models, powerful engine options, and robust build quality.
Key Features
Key Features:	Independent Rear Suspension (IRS) on some models, Polaris Variable Transmission (PVT) with engine braking, robust chassis design, powerful engine options, user-friendly controls, and a focus on rider comfort and capability across varied terrain.

Manual Details
Coverage
Coverage Areas:	General Information, Body, Frame & Mounting, Engine, Suspension, Driveline, Brake System, Transmission/Transaxle, Clutch, Chains, Exhaust, Fuel, Steering, Shocks, Climate Control, Instrumentation & Warnings Systems, Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring, Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Trouble Codes, Wiring Diagrams, Troubleshooting and Diagnostics, Computer Diagnostic Trouble Tree Charts, Engine Performance, Front End and Alignment Procedures and Specifications, Suspension, Transmission Removal and Installation, Air Conditioning Service and Capacities, Transmission In Car Servicing, Computer Diagnostic Codes, Firing Orders, Factory Maintenance Schedules and Charts, Serpentine Belt Routings with Diagrams, Timing Belt Service Procedures, Brake Servicing Procedures, Driving Concerns, Complete Torque Specifications, U-Joint and CV-Joint Service Procedures, Repair Procedures, Complete Wiring Diagrams, Vacuum Diagrams, Engine Mechanical, Engine Coolant, Engine Control System, Emission Control Systems, Drive Shaft, Drive Belt, Differential Case Assy, Cylinder Head Assy, Cylinder Head, Cylinder Block Assy, Cooling System, Cooling Fan System, Combination Meter, Clutch Unit, Clutch System, Clutch Start Switch Assy, Clutch Release Cylinder Assy, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Charging System, Charcoal Canister, Chain Sub-Assy, Center Stop Lamp Assy, Center Cluster Module Switch, Center Air Bag Sensor Assy, Camshaft Position Sensor, Camshaft, Brake System, Brake Pedal, Brake Master Cylinder, Brake Fluid, Brake Booster, Brake Actuator, Body Repair, Yaw Rate Sensor, Wiring Diagrams, Wire Harness Repair, Wiper Rubber, Wiper And Washer System, Wiper & Washer, Windshield Wiper Switch Assy, Windshield Wiper Motor Assy, Windshield Glass, Window Defogger System, Wheel And Tire System, Water Pump Assy, Washer Nozzle, Valve Clearance, Transmission Wire, Transmission Valve Body, Transmission Revolution Sensor, Transmission Control Cable, Torque Converter Clutch, Tire & Wheel, Throttle Body Assy, Thermostat, Supplemental Restraint System, Sun Roof System, Sun Roof, Steering System, Steering Sensor, Steering Column, Starting System, Starter Switch, Starter Assy, Spiral Cable Sub-Assy, Speed Sensor Front, Skid Control Sensor, Side Turn Signal Lamp Assy, Side Mudguard, Side Air Bag Sensor Assy, Shift Lock System, Shift & Select Lever Shaft, Sfi System, Seat Position Air Bag Sensor, Seat Belt Warning System, Seat Belt, Seat, Roof Headlining, Roof Drip Side Finish Moulding, Roof Antenna Pole Sub-Assy, Receiver Condenser Assy, Rear Wiper Rubber, Rear Wiper Motor Assy, Rear Wheel Alignment, Rear Suspension System, Rear Suspension, Rear Speaker Assy, Rear Shock Absorber Assy, Rear Seat Belt, Rear Door Window Frame Moulding, Rear Door Glass Weatherstrip, Rear Door, Rear Combination Lamp Assy, Rear Coil Spring, Rear Bumper, Rear Brake, Rear Axle Hub, Rear Axle Beam, Radio Receiver Assy, Radiator Assy, Quarter Window Assy, Pulley Compressor Assy, Preparation, Power Window Control System, Power Steering Link Assy, Power Steering, Power Source, Power Mirror Control System, Power Door Lock Control System, Passenger Air Bag Assy, Partial Engine, Parkneutral Position Switch, Parking Brake Lever, Parking Brake Cable, Parking Brake, Output Shaft Assy, Outer Rear View Mirror Assy, Oil Pump, Oil Filter, Name Plate, Manual Transaxle System, Manual Transaxle Oil, Manual Transaxle Assy, Maintenance, Lubrication System, Lighting System, License Plate Lamp Assy, Knock Sensor, Introduction, Instrument Panel, Input Shaft Assy, Inner Rear View Mirror Assy, Ignition System, Horn Button Assy, Horn, Hood, Heater Radiator Assy, Heater Or Boost Ventilator Control, Heater & Air Conditioner, Headlamp Protector Retainer, Headlamp Dimmer Switch Assy, Headlamp Assy, Generator Assy, Fuel Tank, Fuel System, Fuel Pump, Fuel Injector, Front Wheel Alignment, Front Suspension System, Front Suspension Arm, Front Suspension, Front Stabilizer Bar, Front Speaker Assy, Front Shock Absorber, Front Seat Belt, Front Seat Airbag Assy, Front Marker Lamp Assy, Front Drive Shaft, Front Door Glass Weatherstrip, Front Door, Front Differential Oil Seal, Front Bumper, Front Brake, Front Axle Hub, Floor Shift Parking Lock Cable, Floor Shift Assy, Fender Panel Mudguard, Exhaust Pipe, Exhaust, Back Door Glass, Back Door Garnish, Back Door, Automatic Transaxle Fluid, Automatic Transaxle Assy, Audio & Visual System, Antenna Cord Sub-Assy, Amplifier Antenna Assy, Air Conditioning System, Air Conditioning Blower Assy, Air Conditioning Amplifier Assy, Air Conditioner Refrigerant, Air Bag Sensor Rear, Air Bag Sensor Front
Identification
Page Count:	Not Specified (PDF format implies variable viewing based on zoom)
Manual Type:	Service and Repair Manual
Language:	English
Format:	PDF Download

Manual Coverage
Systems
Systems Covered:	Engine (all variants), Driveline, Transmission/Transaxle, Clutch, Brakes, Suspension (front and rear), Steering, Fuel System, Exhaust System, Cooling System, Electrical System (including charging, starting, lighting, ignition, instrumentation), Chassis, Body, Frame, Climate Control (if applicable to specific trims), Safety Systems (including supplemental restraint systems/airbags if applicable), Audio Systems, Accessories.
Procedures
Procedures Included:	Complete engine overhaul and rebuilding, troubleshooting and diagnostics, engine performance tuning, front end and alignment procedures, suspension servicing, transmission removal and installation, in-car transmission servicing, brake servicing, timing belt replacement (if applicable), clutch system service, driveline component repair (U-joints, CV-joints), exhaust system repair, fuel system maintenance and repair, steering system service, shock absorber replacement, electrical system diagnostics and repair, wiring harness repair, routine maintenance, lubrication, component replacement, diagnostic code retrieval and interpretation, vacuum system diagnostics.
Depth
Technical Depth:	Comprehensive, covering all aspects from basic maintenance and troubleshooting to complete engine rebuilding and component overhaul. Includes detailed illustrations, exploded diagrams, and step-by-step repair procedures suitable for both novice DIYers and experienced mechanics.

Manual Specifications
File Details
File Format:	PDF
Print Quality:	Printable, allowing users to print specific sections or the entire manual.
Binding Type:	N/A (Digital Download)
Paper Type:	N/A (Digital Format)
Searchability:	Searchable text within the PDF document.
Drm Protection:	Complete Free (No DRM)
Illustration Quality:	Detailed illustrations, exploded diagrams, and photos.

Engine Specifications
Primary Engine
Engine Type:	4-Stroke, Liquid-Cooled, SOHC (Single Overhead Cam), Single-Cylinder
Displacement:	499cc (for 500 models), 375cc (for 400 models, typically)
Performance
Horsepower:	Approx. 30-35 HP (for 500 H.O. models, estimates vary)
Torque:	Specific torque figures vary by engine tune and model, but known for strong low-end and mid-range torque for hauling and climbing.
Fuel System
Fuel Delivery:	Carburetor (likely Mikuni BSR series for 500 models)
Cooling
Cooling System:	Liquid-Cooled
Ignition
Ignition System:	Electronic Ignition (CDI)

Transmission
Standard
Transmission Type:	Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:	2WD/4WD (selectable)
Features
Transmission Features:	Automatic operation with high and low range, reverse, and park. Utilizes a belt-driven CVT system.

Dimensions
Exterior
Length:	Approx. 81 inches (2057 mm)
Width:	Approx. 46 inches (1168 mm)
Height:	Approx. 45 inches (1143 mm)
Weights
Dry Weight:	Approx. 600-650 lbs (272-295 kg), varies by model
Ground Clearance:	Approx. 9-11 inches (229-279 mm)
Cargo
Rack Capacity Front:	275 lbs (125 kg)
Rack Capacity Rear:	400 lbs (181 kg)
Towing
Towing Capacity:	1500 lbs (680 kg)

Safety Features
Ratings
Safety Ratings:	N/A (ATVs are not typically rated by agencies like NHTSA in the same way as cars. User safety depends on adherence to operating guidelines and wearing appropriate safety gear.)
Active Features
Active Features:	Engine braking provided by the PVT, selectable 2WD/4WD for improved traction.
Passive Features
Passive Features:	Robust frame construction, comfortable seating, integrated floorboards with heel guards, and handlebar guards.

Technology Features
Infotainment
Infotainment Features:	Basic instrumentation includes speedometer, odometer, trip meter, fuel gauge, and warning lights. No advanced infotainment systems expected for this model year.
Driver Assistance
Driver Assistance Features:	Limited driver assistance features. Primary assistance comes from the selectable 2WD/4WD system and the engine braking inherent in the PVT.
Connectivity
Connectivity Features:	No electronic connectivity features available.

Maintenance
Service Intervals
Service Intervals:	Refer to manual for specific intervals, but typical services include: Every 25 hours/6 months: Check oil level, check chaincase oil level, inspect brake system, check tire pressure. Every 50 hours/1 year: Change engine oil and filter, change chaincase oil, inspect spark plug, inspect air filter, inspect drive belts, lubricate chassis components. Annually or as needed: Clutch inspection, transmission fluid change, coolant flush.
Fluid Specifications
Engine Oil Type:	API SG or higher, SAE 0W-40 or 5W-30 Synthetic Oil recommended (consult manual for precise viscosity based on temperature).
Chaincase Oil Type:	Polaris Premium ATV Oil or equivalent SAE 0W-40 synthetic gear oil (specific to chaincase).
Coolant Type:	Ethylene glycol-based antifreeze/coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water.
Brake Fluid Type:	DOT 3 or DOT 4 brake fluid.
Known Issues
Known Issues:	Potential issues common to older ATVs of this era can include carburetor tuning difficulties, aging fuel lines, wear on suspension components (bushings, ball joints), drive belt wear, and electrical connection corrosion. The manual would provide detailed troubleshooting for these.

Vehicle History
Brand Heritage
Brand Heritage:	Polaris Industries is an American manufacturer founded in 1954, initially focused on snowmobiles. They expanded into ATVs in the late 1980s, quickly establishing themselves as a major player in the powersports industry with innovative designs and a strong emphasis on performance and durability.
Model Evolution
Model Evolution:	The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades. The 2001 models represent an evolution from earlier generations, incorporating improvements in suspension, power, and rider comfort. The 'H.O.' (High Output) designation signifies enhanced engine performance. The 'DUSE' and 'RSE' variants typically denote specific trim levels or special editions with unique features or graphics.
Production
Production Years Series:	The Polaris Sportsman series has been in continuous production since its introduction, with the 500cc engine platform being a dominant force for many years.

Awards & Recognition
Recognitions
Recognitions:	While specific awards for the 2001 Sportsman 400/500 are not readily documented, Polaris ATVs consistently received praise in enthusiast publications for their performance, reliability, and innovation during this period.