Name: Polaris Sportsman 400 Service manual
Brand: Polaris
Rating: 5 (1 reviews)

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1. Table of Contents
3. GENERAL INFORMATION
4. Replacement Keys
5. Model Color Identification
10. Machine Dimensions
15. Spring Position (Sheave)
19. Publication Numbers
20. Standard Torque Specifications
23. Decimal equivalents
25. Decimal Equivalent Chart
26. Glossary of Terms
28. MAINTENANCE
29. Periodic Maintenance Chart
30. Pre-Ride Inspection
37. Front Gearcase Lubrication
38. Transmission Lubrication
39. Transmission gearshift adjustment
41. Throttle operation
42. Pilot screw adjustment
44. Fuel System
45. Carburetor draining
46. Compression Test
47. Battery Maintenance
48. Spark plug
49. Cooling system hoses
50. Coolant level inspection
52. Air Box Sediment Tube Service
53. Recoil Housing
54. Oil Change/Filter
56. Valve Clearance
57. Intake valve clearance adjustment
62. Exhaust pipe
63. Brake pad inspection
64. Auxiliary brake testing
65. Front suspension
66. Controls
67. Wheel Removal/Installation
68. Tire pressure
69. ENGINE
70. Torque Specifications
71. Torque Patterns
72. Piston Identification
73. Engine Service Data
75. Cooling system
76. Cooling System Specifications
77. Accessible components
78. Engine Removal
79. Engine Installation Notes
80. Honing to oversize
81. Crankshaft straightening
84. EH42PL / EH50PL Engine Lubrication
85. EH42PL / EH50PL Engine Exploded View
87. Cam chain tensioner inspection
88. Rocker arm/shaft inspection
90. Camshaft removal
92. Automatic compression release installati...
93. Camshaft inspection
94. Cylinder head exploded view
95. Cylinder head inspection
96. Cylinder head disassembly
98. Valve inspection
99. Combustion chamber
100. Valve seat reconditioning
104. Cylinder head assembly
105. Valve sealing test
108. Piston removal
109. Cylinder inspection
111. Piston/rod inspection
112. Piston ring installed gap
113. Crankcase disassembly
116. One way valve
117. Crankcase separation
118. Oil pump removal/inspection
120. Oil pump assembly
121. Counter balancer shaft removal/inspectio...
122. Crankshaft removal/inspection
123. Crankcase bearing inspection
124. Crankcase inspection
125. Crankshaft end play adjustment
127. Counter balancer shaft end play adjustme...
128. Pump shaft oil seal installation
129. Crankcase assembly
130. Water pump mechanical seal installation
132. One way valve installation
133. Piston ring installation
134. Piston installation
135. Cylinder and head installation
136. Cylinder head installation
137. Camshaft installation and timing
140. Cam chain tensioner installation
142. Thermostat installation
143. Recoil disassembly/inspection
145. Recoil assembly
150. FUEL SYSTEM/CARBURETION
151. Jetting Guidelines
153. Fuel Flow Diagram
154. Mikuni jet part numbers
155. CV Carburetor System Function (4 Cycle)
156. Mikuni cv carb operation
158. Float system
162. Carburetor cleaning
163. Carburetor inspection
164. Carburetor assembly
165. Float height adjustment
166. Needle and seat leakage test
168. Fuel Pump Exploded View
169. Troubleshooting
173. BODY ASSEMBLY EXPLODED VIEW
174. Cover/Panel Removal
175. Headlight Pod Exploded View
176. Side Panel Removal
177. Steering Assembly, Exploded View
178. A-Arm Replacement
179. Rear Suspension Assembly
180. Strut assembly
181. Front strut cartridge replacement
182. Ball joint replacement
183. Steering Post Assembly
184. PVT SYSTEM
186. PVT System Operation
187. PVT Maintenance/Inspection
188. Pvt overheating
189. PVT Disassembly
191. PVT Assembly
192. PVT Sealing and Ducting Components
194. Drive Clutch Spring Specifications
195. Shift Weights
196. Shift weight inspection
197. Drive Clutch Inspection
198. Drive Clutch Disassembly
199. Spider removal
201. Drive Clutch Assembly
202. Drive Belt Tension
203. Drive Belt Removal/Inspection
204. Drive Belt Installation
205. Clutch Alignment /Offset
206. Drive Clutch Bushing Service
210. Driven Clutch Disassembly/Inspection
213. Driven Clutch Assembly
218. EBS Theory of Operation
220. EBS Exploded View
221. Drive clutch inspection
222. Moveable sheave bushing inspection
230. Troubleshooting
232. FINAL DRIVE
233. Final drive
234. Awd operation overview
237. Awd front hub bearing adjustment
238. Awd front hub exploded view
239. Awd hub seal replacement
241. Hilliard clutch disassembly/inspection
242. AWD Armature Plate Inspection
243. Awd front drive axle removal
244. Awd front drive axle installation
247. Awd front drive axle exploded view
250. Awd front prop shaft removal
251. U-Joint Disassembly
252. U-Joint Assembly
254. Awd front housing removal
256. Awd front housing assembly
258. Awd front housing exploded view
259. Rear hub/bearing carrier removal
261. Rear Hub Installation
262. Rear Hub Disassembly
263. Rear Hub Assembly
264. Rear Drive Shaft Removal
265. Rear Drive Shaft Installation
266. Rear Drive Shaft Service
270. TRANSMISSION
271. Gear Shift Selector Removal
273. Gear Shift Selector Assembly
274. Gear Shift Selector Installation
275. Transmission Removal
278. Transmission Installation
280. Transmission Disassembly
301. Transmission Exploded View
302. Troubleshooting checklist
303. Troubleshooting
304. Specifications
305. Brake System Service Notes
306. Brake Noise Troubleshooting
307. Hydraulic Brake System Operation
308. Dual Hydraulic Caliper Bleeding
310. Fluid Replacement/Bleeding Procedure
312. Master Cylinder Disassembly
314. Master Cylinder Inspection
316. Master Cylinder Installation
317. Front Pad Removal
318. Front Pad Assembly
319. Front Disc Inspection
321. Front Caliper Removal
322. Front Caliper Inspection
323. Front Caliper Assembly
324. Front Caliper Installation
329. Rear caliper assembly
333. Troubleshooting
334. ELECTRICAL
335. Special Tools
336. High beam headlight adjustment
337. Indicator lamp replacement
338. Timing Check Procedure
339. Typical Ignition Timing Curve
340. Flywheel Identification
342. Ignition system
344. Ignition System Troubleshooting
345. Battery Service
346. Battery installation
347. Load test
348. Off season storage
349. Charging System Testing
352. Starter System Troubleshooting
353. Starter system
354. Starter motor disassembly
357. Armature testing
358. Starter assembly
359. Starter Drive
360. Electronic Speedometer Troubleshooting
368. Fan Control Circuit Operation
369. Brake light switch
371. Etc operation test
372. Electrical Notes

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1. Table of Contents
3. GENERAL INFORMATION
4. Replacement Keys
5. Model Color Identification
10. Machine Dimensions
15. Spring Position (Sheave)
19. Publication Numbers
20. Standard Torque Specifications
23. Decimal equivalents
25. Decimal Equivalent Chart
26. Glossary of Terms
28. MAINTENANCE
29. Periodic Maintenance Chart
30. Pre-Ride Inspection
37. Front Gearcase Lubrication
38. Transmission Lubrication
39. Transmission gearshift adjustment
41. Throttle operation
42. Pilot screw adjustment
44. Fuel System
45. Carburetor draining
46. Compression Test
47. Battery Maintenance
48. Spark plug
49. Cooling system hoses
50. Coolant level inspection
52. Air Box Sediment Tube Service
53. Recoil Housing
54. Oil Change/Filter
56. Valve Clearance
57. Intake valve clearance adjustment
62. Exhaust pipe
63. Brake pad inspection
64. Auxiliary brake testing
65. Front suspension
66. Controls
67. Wheel Removal/Installation
68. Tire pressure
69. ENGINE
70. Torque Specifications
71. Torque Patterns
72. Piston Identification
73. Engine Service Data
75. Cooling system
76. Cooling System Specifications
77. Accessible components
78. Engine Removal
79. Engine Installation Notes
80. Honing to oversize
81. Crankshaft straightening
84. EH42PL / EH50PL Engine Lubrication
85. EH42PL / EH50PL Engine Exploded View
87. Cam chain tensioner inspection
88. Rocker arm/shaft inspection
90. Camshaft removal
92. Automatic compression release installati...
93. Camshaft inspection
94. Cylinder head exploded view
95. Cylinder head inspection
96. Cylinder head disassembly
98. Valve inspection
99. Combustion chamber
100. Valve seat reconditioning
104. Cylinder head assembly
105. Valve sealing test
108. Piston removal
109. Cylinder inspection
111. Piston/rod inspection
112. Piston ring installed gap
113. Crankcase disassembly
116. One way valve
117. Crankcase separation
118. Oil pump removal/inspection
120. Oil pump assembly
121. Counter balancer shaft removal/inspectio...
122. Crankshaft removal/inspection
123. Crankcase bearing inspection
124. Crankcase inspection
125. Crankshaft end play adjustment
127. Counter balancer shaft end play adjustme...
128. Pump shaft oil seal installation
129. Crankcase assembly
130. Water pump mechanical seal installation
132. One way valve installation
133. Piston ring installation
134. Piston installation
135. Cylinder and head installation
136. Cylinder head installation
137. Camshaft installation and timing
140. Cam chain tensioner installation
142. Thermostat installation
143. Recoil disassembly/inspection
145. Recoil assembly
150. FUEL SYSTEM/CARBURETION
151. Jetting Guidelines
153. Fuel Flow Diagram
154. Mikuni jet part numbers
155. CV Carburetor System Function (4 Cycle)
156. Mikuni cv carb operation
158. Float system
162. Carburetor cleaning
163. Carburetor inspection
164. Carburetor assembly
165. Float height adjustment
166. Needle and seat leakage test
168. Fuel Pump Exploded View
169. Troubleshooting
173. BODY ASSEMBLY EXPLODED VIEW
174. Cover/Panel Removal
175. Headlight Pod Exploded View
176. Side Panel Removal
177. Steering Assembly, Exploded View
178. A-Arm Replacement
179. Rear Suspension Assembly
180. Strut assembly
181. Front strut cartridge replacement
182. Ball joint replacement
183. Steering Post Assembly
184. PVT SYSTEM
186. PVT System Operation
187. PVT Maintenance/Inspection
188. Pvt overheating
189. PVT Disassembly
191. PVT Assembly
192. PVT Sealing and Ducting Components
194. Drive Clutch Spring Specifications
195. Shift Weights
196. Shift weight inspection
197. Drive Clutch Inspection
198. Drive Clutch Disassembly
199. Spider removal
201. Drive Clutch Assembly
202. Drive Belt Tension
203. Drive Belt Removal/Inspection
204. Drive Belt Installation
205. Clutch Alignment /Offset
206. Drive Clutch Bushing Service
210. Driven Clutch Disassembly/Inspection
213. Driven Clutch Assembly
218. EBS Theory of Operation
220. EBS Exploded View
221. Drive clutch inspection
222. Moveable sheave bushing inspection
230. Troubleshooting
232. FINAL DRIVE
233. Final drive
234. Awd operation overview
237. Awd front hub bearing adjustment
238. Awd front hub exploded view
239. Awd hub seal replacement
241. Hilliard clutch disassembly/inspection
242. AWD Armature Plate Inspection
243. Awd front drive axle removal
244. Awd front drive axle installation
247. Awd front drive axle exploded view
250. Awd front prop shaft removal
251. U-Joint Disassembly
252. U-Joint Assembly
254. Awd front housing removal
256. Awd front housing assembly
258. Awd front housing exploded view
259. Rear hub/bearing carrier removal
261. Rear Hub Installation
262. Rear Hub Disassembly
263. Rear Hub Assembly
264. Rear Drive Shaft Removal
265. Rear Drive Shaft Installation
266. Rear Drive Shaft Service
270. TRANSMISSION
271. Gear Shift Selector Removal
273. Gear Shift Selector Assembly
274. Gear Shift Selector Installation
275. Transmission Removal
278. Transmission Installation
280. Transmission Disassembly
301. Transmission Exploded View
302. Troubleshooting checklist
303. Troubleshooting
304. Specifications
305. Brake System Service Notes
306. Brake Noise Troubleshooting
307. Hydraulic Brake System Operation
308. Dual Hydraulic Caliper Bleeding
310. Fluid Replacement/Bleeding Procedure
312. Master Cylinder Disassembly
314. Master Cylinder Inspection
316. Master Cylinder Installation
317. Front Pad Removal
318. Front Pad Assembly
319. Front Disc Inspection
321. Front Caliper Removal
322. Front Caliper Inspection
323. Front Caliper Assembly
324. Front Caliper Installation
329. Rear caliper assembly
333. Troubleshooting
334. ELECTRICAL
335. Special Tools
336. High beam headlight adjustment
337. Indicator lamp replacement
338. Timing Check Procedure
339. Typical Ignition Timing Curve
340. Flywheel Identification
342. Ignition system
344. Ignition System Troubleshooting
345. Battery Service
346. Battery installation
347. Load test
348. Off season storage
349. Charging System Testing
352. Starter System Troubleshooting
353. Starter system
354. Starter motor disassembly
357. Armature testing
358. Starter assembly
359. Starter Drive
360. Electronic Speedometer Troubleshooting
368. Fan Control Circuit Operation
369. Brake light switch
371. Etc operation test
372. Electrical Notes

Description

The Service Manual of the Polaris Sportsman 400 and Sportsman 500, Sportsman 500 H.O., SPORTSMAN 500 DUSE Offroad Vehicle is designed to provide comprehensive instructions on how to maintain and repair the vehicle. It includes a table of contents that provides detailed information on the model color identification, machine dimensions, electrical system, replacement keys and more. The manual also includes step-by-step instructions on engine maintenance, troubleshooting and repair. It also provides helpful tips on how to properly use and store your vehicle. The Service Manual is an invaluable resource for any user of the Polaris Sportsman 400 and Sportsman 500, Sportsman 500 H.O., SPORTSMAN 500 DUSE Offroad Vehicle. Whether you’re a novice or an experienced rider, the Service Manual will help you keep your vehicle running smoothly. With detailed instructions and helpful tips, the Service Manual will help you keep your Polaris Sportsman running for years to come.

Also for: Sportsman 500, Sportsman 500 H.O., SPORTSMAN 500 DUSE

File size: 38.12 MB

Created: January 31, 2023

Last updated: March 23, 2023