Polaris Sportsman 400 Manuals

Manuals and User Guides for Polaris Sportsman 400. We have 3 Polaris Sportsman 400 manuals available for free PDF download: Service Manual, Owner's Manual, Use And Care Manual

Polaris Sportsman 400 Service Manual

Polaris Sportsman 400 Service Manual (381 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 39.97 MB

Table of Contents

Chapter Index

1
- Table of Contents
  1
- General Information
  3
  - Identification Numbers
    3
- Model Identification
  3
  - Engine Serial Number Location
    3
- Replacement Keys
  4
- Model Color Identification
  5
- Machine Dimensions
  10
  - Spring Position (Sheave)
    15
- Paint Codes
  19
- Publication Numbers
  19
- Standard Torque Specifications
  20
  - Decimal Equivalents
    23
- Decimal Equivalent Chart
  25
  - Sae Tap Drill Sizes
    25
- Glossary of Terms
  26
Chapter 2 Maintenance

28
- Chapter 1
  28
- Periodic Maintenance Chart
  29
- Pre-Ride Inspection
  30
- Front Gearcase Lubrication
  37
- Transmission Lubrication
  38
- Shift Linkage Adjustment
  39
  - Transmission Gearshift Adjustment
    39
  - Throttle Operation
    41
- Idle Speed
  42
- Pilot Screw Adjustment
  42
- Fuel Filter
  44
- Fuel System
  44
- Carburetor Draining
  45
- Compression Test
  46
- Engine Mounts
  46
- Battery Maintenance
  47
- Ignition Timing
  48
- Spark Plug
  48
- Cooling System Hoses
  49
- Coolant Level Inspection
  50
- Radiator Coolant Level Inspection
  50
- Air Box Sediment Tube Service
  52
- Breather Filter Inspection
  52
- Breather Hose
  52
- Recoil Housing
  53
- Engine Oil Level
  54
- Oil Change/Filter
  54
- Valve Clearance
  56
  - Exhaust Valve Clearance Adjustment
    57
  - Intake Valve Clearance Adjustment
    57
  - Exhaust Pipe
    62
  - Brake Pad Inspection
    63
  - Auxiliary Brake Testing
    64
  - Front Suspension
    65
- Rear Suspension
  65
- Controls
  66
- Wheel Removal/Installation
  67
- Tire Inspection
  68
- Tire Pressure
  68
Chapter 3 Engine

69
- Torque Specifications
  70
- Torque Patterns
  71
- Piston Identification
  72
- Engine Service Data
  73
- Cooling System
  75
- Cooling System Specifications
  76
- Accessible Components
  77
- Engine Removal
  78
- Engine Installation Notes
  79
- Cleaning the Cylinder after Honing
  80
- Honing to Oversize
  80
- Crankshaft Straightening
  81
- EH42PL / EH50PL Engine Lubrication
  84
- EH42PL / EH50PL Engine Exploded View
  85
- Cam Chain Tensioner Inspection
  87
- Rocker Arm/Shaft Inspection
  88
- Cylinder Head Inspection
  95
- Cylinder Head Warpage
  95
- Cylinder Head Disassembly
  96
- Valve Inspection
  98
- Combustion Chamber
  99
- Valve Seat Reconditioning
  100
- Cylinder Head Assembly
  104
- Valve Sealing Test
  105
- Piston Removal
  108
- Cylinder Inspection
  109
- Piston/Rod Inspection
  111
- Piston Ring Installed Gap
  112
- Crankcase Disassembly
  113
- Starter Drive Removal/Inspection
  113
- One Way Valve
  116
- Crankcase Separation
  117
- Oil Pump Removal/Inspection
  118
- Oil Pump Assembly
  120
- Counter Balancer Shaft Removal/Inspection
  121
- Crankshaft Removal/Inspection
  122
- Crankcase Bearing Inspection
  123
- Crankcase Inspection
  124
- Crankshaft End Play Adjustment
  125
- Counter Balancer Shaft End Play Adjustment
  127
- Pump Shaft Oil Seal Installation
  128
- Crankcase Assembly
  129
- Water Pump Mechanical Seal Installation
  130
- One Way Valve Installation
  132
- Piston Ring Installation
  133
- Piston Installation
  134
- Cylinder and Head Installation
  135
- Cylinder Installation
  135
- Cylinder Head Installation
  136
  - Camshaft Installation and Timing
    137
  - Camshaft Timing
    137
  - Cam Chain Tensioner Installation
    140
- Oil Pipes
  142
- Thermostat Installation
  142
- Recoil Disassembly/Inspection
  143
- Recoil Assembly
  145
Chapter 4 Fuel System/Carburetion

150
- Jetting Guidelines
  151
- Main Jet Selection
  151
- Fuel Flow Diagram
  153
- Mikuni Jet Part Numbers
  154
- CV Carburetor System Function (4 Cycle)
  155
  - Mikuni CV Carb Operation
    156
  - Float System
    158
  - Main System
    158
  - Carburetor Cleaning
    162
  - Carburetor Inspection
    163
  - Carburetor Assembly
    164
  - Float Height Adjustment
    165
  - Fuel Level
    166
  - Needle and Seat Leakage Test
    166
- Fuel Pump Exploded View
  168
- Troubleshooting
  169
Chapter 5 Body and Steering

171
- Body Assembly Exploded View
  173
- Cover/Panel Removal
  174
- Headlight Pod Exploded View
  175
- Side Panel Removal
  176
- Steering Assembly, Exploded View
  177
- A-Arm Replacement
  178
- Rear Suspension Assembly
  179
- Strut Assembly
  180
  - Front Strut Cartridge Replacement
    181
  - Ball Joint Replacement
    182
- Decal Replacement
  183
Chapter 6 Pvt System

184
- Steering Post Assembly
  183
- Chapter 5
  184
- Drive Clutch Operation
  186
- Driven Clutch Operation
  186
- PVT System Operation
  186
- Pvt Drying
  187
- PVT Maintenance/Inspection
  187
- Pvt Overheating
  188
- PVT Disassembly
  189
- PVT Assembly
  191
- PVT Sealing and Ducting Components
  192
- Drive Clutch Spring Specifications
  194
- Shift Weights
  195
  - Button to Tower Clearance Inspection
    196
  - Shift Weight Inspection
    196
- Drive Clutch Exploded View
  197
- Drive Clutch Inspection
  197
- Drive Clutch Disassembly
  198
- Spider Removal
  199
- Drive Clutch Assembly
  201
- Drive Belt Tension
  202
- Drive Belt Removal/Inspection
  203
- Drive Belt Installation
  204
- Clutch Alignment /Offset
  205
- Drive Clutch Bushing Service
  206
- Driven Clutch Disassembly/Inspection
  210
- Driven Clutch Assembly
  213
- EBS Theory of Operation
  218
- EBS Exploded View
  220
- Drive Clutch Inspection
  221
- Moveable Sheave Bushing Inspection
  222
- Troubleshooting
  230
Chapter 7 Final Drive 7

232
- Final Drive
  233
  - Awd Operation Overview
    234
    
    Awd Front Hub Bearing Adjustment
    237
    
    Awd Front Hub Exploded View
    238
    
    Awd Hub Seal Replacement
    239
  - Hilliard Clutch Disassembly/Inspection
    241
  - AWD Armature Plate Inspection
    242
    
    Awd Front Drive Axle Removal
    243
    
    Awd Front Drive Axle Installation
    244
    
    Awd Front Drive Axle Exploded View
    247
    
    Awd Front Prop Shaft Removal
    250
  - U-Joint Disassembly
    251
  - U-Joint Assembly
    252
    
    Awd Front Housing Removal
    254
    
    Awd Front Housing Assembly
    256
    
    Awd Front Housing Exploded View
    258
  - Rear Hub/Bearing Carrier Removal
    259
  - Rear Hub Installation
    261
  - Rear Hub Disassembly
    262
  - Rear Hub Assembly
    263
  - Rear Drive Shaft Removal
    264
  - Rear Drive Shaft Installation
    265
  - Rear Drive Shaft Service
    266
Chapter 8 Transmission Service

269
- Torque Specifications
  270
- Gear Shift Selector Disassembly
  271
- Gear Shift Selector Removal
  271
- Gear Shift Selector Assembly
  273
- Boot Replacement
  274
- Gear Shift Selector Installation
  274
- Transmission Removal
  275
- Transmission Installation
  278
- Transmission Disassembly
  280
- Transmission Exploded View
  301
- Troubleshooting Checklist
  302
Chapter 9 Brakes

303
- Troubleshooting
  303
- Specifications
  304
  - Brake System Service Notes
    305
  - Brake Pad Kits
    305
  - Brake Noise Troubleshooting
    306
  - Hydraulic Brake System Operation
    307
  - Dual Hydraulic Caliper Bleeding
    308
  - Fluid Replacement/Bleeding Procedure
    310
  - Master Cylinder Disassembly
    312
  - Master Cylinder Inspection
    314
  - Master Cylinder Assembly
    314
  - Master Cylinder Installation
    316
  - Front Pad Removal
    317
  - Front Pad Assembly
    318
  - Front Disc Inspection
    319
  - Front Caliper Removal
    321
  - Front Caliper Disassembly
    321
  - Front Caliper Inspection
    322
  - Front Caliper Assembly
    323
  - Front Caliper Installation
    324
  - Rear Caliper Assembly
    329
  - Troubleshooting
    333
Chapter 10 Electrical

334
- Chapter 9
  334
- Special Tools
  335
  - Electrical Service Notes
    335
  - High Beam Headlight Adjustment
    336
  - Indicator Lamp Replacement
    337
- Timing Check Procedure
  338
- Typical Ignition Timing Curve
  339
- Flywheel Identification
  340
  - Ignition System
    342
- Ignition System Troubleshooting
  344
- Battery Service
  345
  - Battery Installation
    346
  - Load Test
    347
  - Specific Gravity Test
    347
    
    Off Season Storage
    348
    
    Charging Procedure
    348
- Charging System Testing
  349
- Starter System Troubleshooting
  352
  - Voltage Drop Test
    352
  - Starter System
    353
  - Starter Motor Disassembly
    354
  - Armature Testing
    357
  - Starter Assembly
    358
- Starter Drive
  359
- Electronic Speedometer Troubleshooting
  360
- Fan Control Circuit Operation
  368
  - Brake Light Switch
    369
  - Etc Operation Test
    371
- Electrical Notes
  372

Polaris Sportsman 400 Owner's Manual

Polaris Sportsman 400 Owner's Manual (153 pages)

Polaris 2003 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 2.68 MB

Table of Contents

Welcome
5
Table of Contents
7
Vehicle Identification Numbers
8
- Age Restrictions
  9
- Operator Safety
  10
Safety
9
- Equipment Modifications
  13
- Safety Decals and Locations
  34
- Safe Riding Gear
  38
- Electrical Switches
  39
- Throttle Lever
  40
Controls
39
- Light Switches
  41
- Brake Lever
  42
- Parking Brake
  43
  - Auxiliary Brake
    44
  - Fuel Filter
    45
  - Fuel Tank
    45
  - Fuel Valve
    45
  - Fuel Safety
    46
  - Belt Life
    48
- Recoil Starter
  49
Engaging Wheel Hubs
50
Features
50
- Disengaging Wheel Hubs
  51
- Indicator Lights
  52
- Instrument Cluster
  53
- Rider Information Center
  54
  - Diagnostic Mode
    57
  - Break-In Period
    58
- Starting a Cold Engine
  61
- Starting the Engine
  61
- Starting a Warm Engine
  62
Operation
58
- Hauling Cargo
  63
- Driving Procedures
  65
- Driving Safely
  65
- Making Turns
  66
- Driving on Slippery Surfaces
  67
- Driving Uphill
  68
- Driving Downhill
  70
- Turning Around on a Hill
  71
  - Driving through Water
    72
  - Driving over Obstacles
    73
  - Driving in Reverse
    74
- Parking on an Incline
  75
Noise Emission Control System Regulation
76
- Usfs Approved Spark Arrestor
  76
Maintenance and Lubrication
77
- Periodic Maintenance Schedule
  78
- Lubrication Recommendations
  82
- Premium 2-Cycle Oil
  87
- Premium Gold Synthetic 2-Cycle Oil
  87
- Premium 4 Synthetic Oil
  88
- Transmission Oil Change - Sportsman
  96
  - Front Gearcase Oil Change
    97
  - Front Gearcase Oil Check
    97
- Rear Gearcase Oil Change
  98
- Rear Gearcase Oil Check
  98
  - Engine Oil Check
    100
  - Coolant Level
    101
  - Engine Cooling System
    101
- Radiator Coolant Level
  102
- Oil Pump Bleeding - 2-Cycle Engines
  103
- Front Brake
  106
- Rear Brake
  107
- Toe Alignment
  108
- Camber and Caster
  109
- Rear Spring
  109
- Steering Assembly
  109
  - Adjusting Carburetor/2-Cycle Engines
    111
  - Adjustments
    111
- Throttle Cable Freeplay
  112
- Side Panel Removal - Gen IV
  113
- Wheel Removal
  114
- Wheel Installation
  115
- Wheel Nut Torque Specifications
  115
- Front Wheel Hub Tightening
  116
- Tire Tread Depth
  116
  - Drive Chain
    117
  - Filter Systems
    120
  - Headlight Lamp Replacement - Scrambler
    122
  - High Beam Adjustment - Scrambler
    122
  - Headlight Adjustment - Trail Blazer
    123
  - Headlight Lamp Replacement - Trail Blazer
    123
  - Headlight Lamp Replacement - Gen IV
    124
  - High Beam Adjustment - Gen IV
    125
  - Headlight Housing Replacement - Gen IV
    126
  - Indicator Lamp Replacement
    127
- Taillight/Brakelight Lamp Replacement
  127
- Spark Plug Removal and Replacement
  128
- Spark Plugs
  128
- Vehicle Immersion
  129
- Spark Arrestor
  130
- Recoil Housing
  132
  - High Range
    133
  - Low Range
    133
- Pvt System
  133
- Pvt Drying
  134
  - Battery (Conventional)
    135
  - Battery Removal
    136
  - Battery Installation
    137
  - Battery Storage
    137
  - Cleaning and Storage
    139
  - Cleaning the Atv
    139
- Washing the Atv
  139
- Waxing the Atv
  139
- Fluid Levels
  140
- Storage Tips
  141
- Transporting the Atv
  142
Polaris Recommended Products
143
Troubleshooting
144
Warranty
148
Engine Oil
150
Index
151

Polaris Sportsman 400 Use And Care Manual

Polaris Sportsman 400 Use And Care Manual (40 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 8.03 MB

Table of Contents

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