Let’s be honest, there’s a reason you still see so many 1999 Polaris Sportsman 500s kicking around on trails and farms. These things are legendary workhorses. They were built tough, they’re relatively simple to work on, and they just keep going. But owning one of these classic ATVs, whether it’s a new-to-you project or a long-time family rig, means you need to know it inside and out.
You’ve probably searched for the basic numbers, but a spec sheet is just a list until you understand what it means for your machine’s health and performance. We promise this is more than just a list of numbers. This is your complete 1999 polaris sportsman 500 specs guide, designed to turn that data into practical knowledge.
In this deep dive, we’ll break down the critical engine, fluid, and chassis specs. More importantly, we’ll show you how to use this information to perform maintenance, troubleshoot common problems, and keep your trusty ’99 Sportsman 500 running like the champion it is. Let’s get those hands dirty.
The Heart of the Beast: Engine & Drivetrain Specs
The engine and transmission are the core of your ATV’s personality and capability. Understanding these specs is the first step in diagnosing issues or planning performance upgrades. This is the foundation of any good 1999 polaris sportsman 500 specs care guide.
Engine Specifications Breakdown
The ’99 Sportsman 500 is powered by a robust and reliable single-cylinder engine that has stood the test of time. It’s a motor known for its low-end torque, perfect for work or technical trail riding.
- Engine Type: 4-Stroke, Single Cylinder
- Displacement: 499cc
- Cooling: Liquid-Cooled
- Bore x Stroke: 92mm x 75mm
- Carburetion: Mikuni BST34
- Starting System: Electric with recoil backup
That Mikuni BST34 carburetor is a key component. While reliable, it’s often the source of running issues on a machine this age. Knowing the model is the first step to finding the right rebuild kit or tuning information.
Transmission & Drive System
Polaris revolutionized the ATV world with its automatic transmission and selectable all-wheel-drive system. It’s a system that’s still impressive today, but it requires the right maintenance to function properly.
- Transmission: Polaris Variable Transmission (PVT) – Automatic F/N/R
- Drive System: Shaft Drive
- 4WD System: On-Demand True All-Wheel Drive (AWD) / 2WD
The Polaris Variable Transmission (PVT) is a belt-driven CVT system. This means keeping an eye on belt condition is crucial. The On-Demand AWD is a brilliant system that automatically engages the front wheels when the rear wheels slip, but it relies on specific fluids and clean electrical connections to work.
Fluids & Capacities: The Lifeblood of Your ’99 Sportsman
Ignoring fluid specs is the fastest way to cause expensive damage. Using the right type and amount of fluid is the single most important part of DIY maintenance. Consider this section your go-to cheat sheet.
Engine Oil
The engine oil lubricates, cools, and cleans the most critical parts of your motor. Don’t cheap out here.
- Recommended Oil: Polaris PS-4 Full Synthetic (or a suitable 0W-40 4-stroke ATV/motorcycle oil)
- Capacity: Approximately 2 quarts (1.9 L)
Pro Tip: Always check the level using the dipstick after an oil change. Start the engine, let it run for 30 seconds, shut it off, wait a minute, and then check the level. This ensures the oil has circulated properly for an accurate reading.
Coolant
The liquid-cooling system is vital for preventing overheating, especially on slow, technical trails. The benefits of using the correct 1999 polaris sportsman 500 specs for coolant cannot be overstated.
- Recommended Coolant: Polaris Antifreeze 60/40 (or a high-quality ethylene glycol-based coolant)
- Capacity: 2.6 quarts (2.5 L)
When you refill the system, be sure to bleed any air pockets out. Trapped air can cause mysterious overheating issues that are hard to diagnose.
Transmission & Gearcase Fluids
This is where many owners get confused. The Sportsman 500 has multiple gearcases that require specific fluids. Using the wrong one will cause damage, especially to the AWD system.
- Transmission: Polaris AGL Synthetic Gearcase Lube (approx. 33.8 oz / 1000 ml)
- Front Gearcase: Polaris Demand Drive Fluid (approx. 9.3 oz / 275 ml)
- Rear Gearcase: Polaris AGL Synthetic Gearcase Lube (approx. 13.5 oz / 400 ml)
Pay close attention here. Using regular gear oil in the front gearcase will cause the AWD system to fail. You must use Polaris Demand Drive Fluid or a compatible equivalent.
Understanding the Chassis: Suspension, Brakes, and Dimensions
The numbers here translate directly to how your ATV handles on the trail, what it can carry, and where it can go. Knowing these specs helps you choose the right tires or understand its limits.
Suspension System
The ’99 Sportsman was known for its plush ride, thanks to its independent front suspension.
- Front Suspension: MacPherson Strut with 8.2 inches (20.8 cm) of travel
- Rear Suspension: Progressive Rate Swingarm with 8.5 inches (21.6 cm) of travel
That generous travel is what allows the wheels to articulate over rocks and ruts, keeping the ride smooth and the tires on the ground for traction.
Brakes, Wheels & Tires
Stock specs are your baseline for maintenance and upgrades. Knowing your bolt pattern is essential before you order those new wheels!
- Front Brakes: Single Lever Hydraulic Disc
- Rear Brakes: Hydraulic Rear Foot Brake
- Stock Front Tires: 25 x 8-12
- Stock Rear Tires: 25 x 11-10
- Wheel Bolt Pattern: 4×156
Key Dimensions & Weight
These numbers dictate how the machine fits in your truck, on your trailer, and through tight trails.
- Dry Weight: 697 lbs (316 kg)
- Wheelbase: 50.5 inches (128.3 cm)
- Length/Width/Height: 83 in / 46 in / 47 in
- Ground Clearance: 7.25 inches (18.4 cm) at its lowest point
- Towing Capacity: 1225 lbs (555.7 kg)
- Fuel Capacity: 5.25 gallons (19.9 L)
Common Problems Linked to 1999 Polaris Sportsman 500 Specs
Every machine has its quirks. After decades on the trail, the common problems with the 1999 Sportsman 500 are well-known. The great news is that they are often directly related to the specs we’ve just covered, making them predictable and fixable.
Carburetor Headaches
The Mikuni BST34 carb can get gummed up from old fuel, leading to hard starting, bogging on acceleration, or a rough idle. Knowing the model number is your key to ordering the right rebuild kit (jets, gaskets, float needle) to bring it back to life.
AWD Engagement Failures
If your AWD isn’t working, the first place to check is the fluid in the front gearcase. As mentioned, it must be Polaris Demand Drive Fluid. The wrong fluid or low fluid levels will prevent the internal clutch mechanism (the Hilliard clutch) from engaging the front wheels.
Overheating Woes
An overheating engine is often traced back to the cooling system specs. Is the coolant level correct (2.6 quarts)? Is the coolant old and broken down? Often, the culprit is a faulty radiator fan switch or a mud-caked radiator that can’t dissipate heat effectively.
Premature Camshaft Wear
Some earlier models were known for camshaft lobe wear. This is almost always accelerated by poor maintenance. Using the wrong type of engine oil or extending oil change intervals can starve the top end of proper lubrication, leading to costly engine damage. Stick to the recommended 0W-40 synthetic oil spec!
A Practical 1999 Polaris Sportsman 500 Specs Guide for Maintenance
Knowing the numbers is one thing; using them is another. Here are some 1999 polaris sportsman 500 specs best practices to apply this knowledge in your garage.
Performing a Basic Service
Use the specs as your checklist:
- Change engine oil (2 quarts of 0W-40) and filter.
- Check and top off coolant (2.6-quart system capacity).
- Inspect and clean the air filter.
- Check all gearcase fluid levels (Transmission, Front, and Rear).
- Check tire pressure (refer to tire sidewall, typically 5-7 PSI).
Choosing the Right Parts
Need new tires? Now you know the stock sizes (25×8-12 front, 25×11-10 rear) and the bolt pattern (4×156). Ordering a carb kit? You know you need one for a Mikuni BST34. This knowledge saves you time, money, and the frustration of returns.
Sustainable Ownership and Eco-Friendly Practices
Being a responsible rider includes caring for the environment. Knowing your fluid capacities helps you purchase the right amount, reducing waste. Always take used oil and coolant to a local auto parts store or recycling center for proper disposal. A well-tuned machine, following the original eco-friendly 1999 polaris sportsman 500 specs for fuel and air mixture, will burn cleaner and be more efficient on the trail.
Frequently Asked Questions About 1999 Polaris Sportsman 500 Specs
What is the top speed of a 1999 Polaris Sportsman 500?
Under ideal conditions, a stock 1999 Sportsman 500 can reach a top speed of around 50-55 mph. However, factors like rider weight, tire condition, and terrain will affect the actual top speed.
How much can a 1999 Sportsman 500 tow?
The official towing capacity is an impressive 1225 lbs from the standard receiver hitch. Its strong low-end torque makes it an excellent machine for yard work and hauling.
What kind of oil does a 1999 Polaris Sportsman 500 take?
The recommended engine oil is a 0W-40 full synthetic 4-stroke ATV/motorcycle oil, such as Polaris PS-4. Do not use standard car oil, as it lacks the additives needed for the transmission and clutch systems in some powersports applications.
Is the 1999 Polaris Sportsman 500 a reliable ATV?
Yes, it is widely regarded as one of the most reliable ATVs ever built. With regular maintenance following the correct fluid and service specs, these machines can last for decades. Their common issues are well-documented and relatively easy to fix for a DIY mechanic.
There you have it—the complete breakdown of the 1999 polaris sportsman 500 specs. This isn’t just data; it’s your roadmap to keeping a classic ATV alive and kicking. These machines represent a golden era of simple, tough, and capable off-roaders.
By understanding what makes your Sportsman tick, you’re empowered to tackle maintenance, solve problems, and make smart decisions about its care. Now you have the knowledge. Grab your tools, get out in the garage, and keep that legendary machine running strong for years to come. Stay safe and happy riding!
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