Service Hints - Polaris 1999 Sportsman 400 Service Manual

cause gasoline is used so
often,
many people forget
that it is a da ngerous prod uct. Gasoline sho uld be
used only as fuel for internal-combustion engines.
Never usc
gas oline
to clean parts, tools or to
wa sh
hands. When working on an ATV. motorcycle or
any other type of gasoline engine. gasoline will al-
ways be present in tbe fuel tank, fue l line and carbu-
retor. To avoid a disastrous accident when working
around gasoline or on the fuel system, carefully ob-
serve the following precautions:
I. Never
usc gasoline to clean parts. See
Cleaning
Part s
in this chapter for additional information
on
pans cleaning and sa fety.
2. Wh en working on the fuel sys tem, work outside
or in a well-ven tilated area.
3. Do not add fuel to the fuel tank or serv ice the fue l
system while the ATV is in the vic inity o f open
flames, sparksor where someoneissmoking. Gaso-
line vapors arc actually more dangerous than liquid
gasoline. Because these vapors are heavier than air.
they collect in low areas and are easily ignited.
4 . Allow the engine to cool completel y before
working on any fuel
system
component.
5. When drai ning the car bure tor, ca tch the gaso line
in a plastic container and then pour it into a
safety-approved gas can.
6. Do not store gasoline in any type of glass con-
tainer. If the glass shoold break . a serious explos ion
or fire could occur.
7. Wipe up spilled gasoline immediately with dry
rags.
Store the
rags
in a metal container with a lid
on til they can be properly disposed of. o r put them
outside in a
safe place to dry.
8. Do
not
pour water onto a gasoline tire. Water
spreads the lire
and
makes it
more difficult
to put
oot. Use a C lass B. BC . or AIlC fire extingu isher to
smother the names and put the fire out.
9. Always tum the engine off before refu elin g. Usc
a
wide-mouth funnel to prevent spilling gasoline
onto the engine. exhaust pipe or
muffler.
Do not
overfill the fuel tank. Leave anairspace
at
the topof
the fue l tank to preven t fue l from spi lling o ut when
insta lling the ca p.
10. A lways refue l the ATV wh ile it is parked out-
side and away from all open flames and sparks.
II . When transporting the ATV in anoth er vehi cle.
keep it upright with the fue l valve turned oiT.
12. Do not perform a spark test (as described in
Chapter Two ) if there is any gasoline leaking from
the
fuel
tank, fuel line or carburetor.
CIIAI'TER O~E
FRONT
REAR
SERVICE HINTS
~
..Iost of the service procedures covered are
straightfo rward and can be performed by anyone
reasonably handy wi th too ls. It is suggested. how-
eve r. that the personal capabilities be carefully eon -
sidercd before attemp ting any operation involving
major disassembly of the engine.
Take time and do the job right. Do not forget that
a
newly
rebuilt engine must be broken in the same
wayas a
new one. Refer to the
Engine Break-In
pro-
ccdure listed in Chapter Four and Chapter Five .
J.
Front, as used in this manual, refers to the front
o f the vehicle; the front ofany component is the end
closest to the front of the vehicle. Th e left and right
sides refer to the position afth e parts as
viewed
by a
rider sitting
011
the seat rac ing forward. For exam-
ple, the throttle
control is on the right side.
These
rules
aresimple. but confusion can cause a major in-
convenience
during service. Sec Figure 1.
2.
Whenever servicing an engine or suspension
component, secure the vehicle in a safe manner.
3. Tag all similar internal parts for location and
mark all mating parts fo r position. Record number