Table Of Contents - Polaris 1999 Sportsman 400 Service Manual

Table of Contents

Table Of Contents1
Quick Reference Data5
Tire Inflation Pressure5
Recommended Lubricants, Fluids And Capacities5
Recommended Capacities5
Maintenance And Tune-Up Torque Specifications6
Maintenance And Tune-Up Specifications6
Replacement Bulbs6
General Information7
Manual Organization7
Chapter One7
Notes, Cautions And Warnings8
Safety First8
Cleaning Parts9
Handling Gasoline Safely9
Service Hints10
Torque Specifications12
Fas Teners12
Iso Metric Screw Threads13
Machine Screws13
Nuts13
Self-Locking Fasteners14
Washers14
Cotter Pins14
Circlips14
Lubricants15
Engine Oil15
Threadlocking Compound16
Rtv Gasket Sealant16
Expendable Supplies16
Grease16
Serial Numbers17
Warning And Information Labels18
Basic Hand Tools18
Screwdrivers18
Pliers18
Locking Pliers19
Circlip Pliers19
Box, Open-End And Combination Wrenches19
Adjustable Wrenches19
Socket Wrenches20
Allen Wrenches20
Torque Wrench20
Impact Driver20
Precision Measuring Tools21
Feeler Gauge21
Vernier Caliper, Dial Caliper And Digital Electronic Caliper21
Outside Micrometers21
Micrometer Range22
How To Read A Micrometer22
Standard Inch Micrometer22
Decimal Place Values23
Vernier Inch Micrometer24
Standard Metric Micrometer25
Micrometer Accuracy Check26
Proper Care Of A Micrometer28
Cylinder Bore Gauge28
Small Hole Gauges28
Telescoping Gauges29
Multimeter29
Voltage29
Resistance30
To Calibrate An Analog Ohmmeter30
Continuity Test30
Amperage30
Special Tools31
Fabricating Tools31
Mechanic's Tips31
Removing Frozen Nuts And Screws31
Bearing Replacement32
Bearing Removal32
Removing Broken Screws And Bolts32
Bearing Installation34
Shrink Fit34
Seals35
Storage36
Selecting A Storage Area36
Preparing Vehicle For Storage36
After Storage37
Model Year And Number37
General Dimensions38
Vehicle Weight (Dry)38
Decimal And Metric Equivalents38
General Torque Specifications39
Conversoin Tables39
Technical Abbreviations40
Metric Tap And Drill Sizes41
Troubleshooting42
Operating Requirements42
Chapter Two42
Troubleshooting Instruments43
Starting The Engine43
Starting A Cold Engine43
Starting Difficulties44
Starting A Warm Or Hot Engine44
Starting A Flooded Engine44
Engine Fails To Start (Spark Test)45
Engine Is Difficult To Start46
Engine Starting System47
Engine Compression47
Poor Idle Speed Performance47
Poor Medium - And High-Speed Performance47
Charging System48
Starter Troubleshooting48
Ignition System49
Ignition System Precautions49
Switch Test49
Ignition Coil Test49
Electronic Throttle Control Switch Testing51
Fuel System52
Engine Overheating52
Engine Preignition52
Engine Detonation52
Engine Noises53
Cylinder Leakdown Test53
Power Loss53
Piston Seizure53
Power Train54
Low Engine Operating Speed54
Engine Operating Speed Too High54
Engine Speed Erratic During Speed Or Load Changes54
Steering55
Drive Belt Not Operating Smoothly In Primary Sheave55
Glazed Drive Belt55
Erratic Shifting55
Disc Brake Troubleshooting56
Frame Noise57
Brakes57
Generally Poor Or Unpredictable Handling57
Loose Steering57
Electrical Specifications58
Lubrication, Maintenance And Tune-Up59
Pre-Ride Checklist59
Tires And Wheels61
Tire Pressure61
Tire Inspection61
Battery62
Rim Inspection62
Safety Precautions62
Electrolyte Level Check63
Battery Removal/Installation63
Cleaning, Inspection And Adding Water64
Battery Testing65
Charging66
New Battery Installation66
Battery Electrical Cable Connectors67
Periodic Lubrication67
Engine Oil Level Check67
Engine Oil And Filter Change68
Engine Oil Pressure Test70
Transmission Oil Level Check71
Transmission Oil Change71
Front Gearcase Oil Level Check72
Front Gearcase Oil Change72
Grease Service73
Front Hub Oil Level Check74
Front Hub Oil Change74
Periodic Maintenance76
Control Cable Lubrication76
Drive Belt Inspection76
Disc Brake System Inspection76
Disc Brake Fluid Level Check And Fill77
Disc Brake Hoses77
Auxiliary Brake Testing And Adjustment78
Throttle Cable/Electronic Throttle Control Adjustment78
Throttle Cable Adjustment79
Air Filter Element80
Coolant Inspection81
Coolant Change82
Exhaust System84
Fuel Hose Inspection85
Fuel Filter Replacement85
Steering System And Front Suspension Inspection85
Front Wheel Toe-Out86
Front Hub Wheel Bearings87
Rear Suspension87
Nuts, Bolts And Other Fasteners87
Wire Harness, Control Cables And Hose Lines87
Unscheduled Inspection And Maintenance88
Recoil Starter88
Body Fasteners88
Fuel Tank And Lines88
Valve Clearance Measurement89
Valve Clearance Adjustment90
Cam Chain Adjustment91
Spark Plug Heat Range91
Spark Plug Removal91
Gapping And Installing The Spark Plug92
Reading Spark Plugs92
Normal Condition93
Carbon-Fouled93
Oil-Fouled93
Gap Bridging93
Spark Plug Condition94
Worn Out95
Preignition95
Checking Ignition Timing95
Adjusting Ignition Timing95
Carburetor Idle Mixture Adjustment96
Idle Speed97
Maintenance And Lubrication Schedule97
Recommended Lubricants And Fluids98
Capacities99
Engine Top End100
Engine Principles100
Engine Cooling100
Four-Stroke Operating Principles101
Engine Lubrication102
Servicing The Engine In The Frame102
Cylinder Head Cover105
Rocker Arm Assembly105
Rocker Arm107
Camshaft Removal109
Camshaft Inspection110
Automatic Compression Release Mechanism Testing112
Camshaft Installation113
Cylinder Head Removal116
Cylinder Head Inspection117
Cylinder Head Installation118
Valves And Valve Components119
Solvent Test120
Valve Removal120
Valve Inspection121
Valve Troubleshooting122
Valve Installation123
Valve Guide Replacement124
Valve Lapping124
Cylinder Block Removal125
Cylinder Block Inspection126
Cylinder Block Installation128
Spec Ial Tools128
Piston And Piston Rings130
Piston Removal130
Piston Inspection131
Piston Pin Inspection133
Piston Clearance133
Piston Installation134
Piston Ring Inspection And Removal134
Piston Ring Installation136
Camshaft Chain And Sprockets Removal137
Camshaft Chain And Sprockets Inspection138
Camshaft Chain And Sprockets Installation139
Camshaft Chain Wear139
Break-In Procedure140
General Engine Specifications140
Engine Lubrication System140
Engine Top End Tightening Torque Specifications141
Engine Top End Specifications141
Engine Lower End143
Engine143
Engine Removal144
Flywheel And Stator Plate Removal147
Flywheel And Stator Plate Installation149
Recoil Starter Removal/Installation150
Recoil Starter Disassembly And Starter Rope Removal150
Recoil Starter Inspection And Assembly150
Crankcase152
Crankcase Separation153
Crankcase Inspection156
Crankshaft Seal Replacement156
Crankcase Bearing Replacement157
Water Pump Mechanical Seal And Bearing Replacement161
Crankcase Assembly162
Crankshaft Inspection168
Crankshaft And Balancer169
Balancer Shaft Inspection169
Shaft End Float Measurement And Shim Selection169
Crankshaft End Play171
Balancer Shaft End Play172
Oil Pump Removal/Disassembly174
Oil Pump Inspection174
Oil Pump Assembly/Installation177
Oil System One-Way Check Valve178
Oil System One-Way Check Valve Break-In Procedure179
Engine Lower End Torque Specifications180
Engine Lower End Specifications180
Carburetor Operation181
Carburetor Removal/Installation182
Carburetor Disassembly183
Mikuni Carburetor 34 Mm184
Carburetor Cleaning And Inspection189
Carburetor Tests And Adjustments192
Inlet Valve Seat Inspection192
Float Level Height Adjustment192
Jet Needle Adjustment193
Main Jet Replacement193
Throttle Cable Replacement194
Starting Enrichment (Choke) Cable Removal/Installation194
Fuel Tank Removal/Installation196
Fuel Shutoff Valve197
Air Filter Air Box Removal/Installation198
Fuel Pump Testing198
Fuel Pump Removal/Installation202
Fuel Pump Disassembly/Assembly203
Carburetor Specifications203
Cooling Systems204
Polaris Variable Transmission (Pvt) Air Cooling System204
Pvt Cooling System205
Clutch Outer And Inner Cover Ducting205
Clutch Outer Cover Removal/Installation205
Clutch Inner Cover Removal/Installation206
Engine Cooling System208
Liquid Cooling System (Typical)209
Hoses And Hose Clamps210
Engine Gaskets/Seals210
Radiator Assembly211
Cooling System Inspection211
Radiator Removal/Installation211
Radiator Inspection214
Cooling Fan Removal/Installation215
Thermostat Removal/Installation217
Temperature Sensors218
Cooling System Specifications218
Clutch/Drive Belt System219
Drive Unit219
Drive Pulley221
Fixed And Sliding Pulley Halves221
Drive Pulley Spring221
Eng Ine No Ises221
Driven Pulley222
Centrifugal Weight Levers222
Release Spring222
Power Tra In222
Drive Belt224
Torque Sensing Cam Angle224
Drive Belt Deflection226
Pulley Center-To-Center Distance227
Drive Belt Alignment227
Pulley Alignment228
Pulley Offset228
Drive Pulley Removal230
Drive Pulley Bolt Inspection241
Clutch Outer And Iinner Cover252
Drive Belt And Pulley Specifications253
Drive Pulley Spring Specifications254
Shift Weights And Driven Pulley Specifications254
Tightening Torque Specifications254
Transmission255
Transmission Service Notes255
Transmission Removal/Installation256
Transmission Case Disassembly258
Transmission Case259
Transmission Case Assembly265
Transmission Shafts Disassembly273
Transmission Shafts Assembly273
Transmission Inspection276
Gear Shafts And Shift Forks277
Shift Shafts Removal/Inspection/Installation280
Front Output Shaft281
Output Shaft End Play Inspection And Adjustment285
Output Shaft Gear Backlash Inspection And Adjustment286
Transmission Gearcase Oil Seal Inspection And Replacement287
Shift Selector Linkage287
Checking And Preliminary Adjustment287
Shift Selector Removal/Installation289
Boot Replacement290
Gearshift Selector290
Transmission And Shift Linkage Torque Specifications295
Transmission Specifications295
Front Drive System296
Front Hub And Hillard Clutch296
Front Electric Hub Clutch299
Hillard Clutch Testing300
Front Hub Seal Replacement302
Front Drive Axle, Boots And Cv (Constant Velocity) Joints304
Front Drive Shaft Removal/Installation307
Front Drive Unit Removal/Installation307
Tire Size And Inflation Pressure308
Front Wheel Drive Hub Specifications308
Electrical System309
Basic Information309
Electrical Component Resistance Testing309
Negative Battery Terminal310
Electrical Component Replacement310
Electrical Connector Location310
Charging System Output Test310
Charging System Amperage Test314
Alternator Stator315
Exciter Coils Testing315
Battery Charge Coils Testing315
Alternator Output Test315
Voltage Regulator/Rectifier316
Capacitor Discharge Ignition316
Cdi Precautions316
Cdi Unit Replacement316
Ignition Coil320
Performance Test320
Ignition Stator Coils321
Electric Starting System321
Starter Drive Gears330
Starter Solenoid330
Starter Solenoid Resistance Test330
Lighting System331
High-Beam Headlight331
Bulb Replacement331
Headlight And Pod332
High-Beam Headlight Adjustment334
High-Beam Headlight Case Removal/Installation334
Grille-Mounted Low-Beam Headlight Bulb Replacement334
Taillight/Brake Light Bulb And Lens Replacement335
Indicator Lamp Replacement335
Electrical Components336
Speedometer Removal/Installation336
Speed Sensor Removal/Installation336
Switches337
Testing337
Right Handlebar Switch Housing Replacement338
Left Handlebar Switch Housing Replacement339
Key Switch Or Ignition Switch Replacement340
Transmission Switch340
Wiring Diagrams341
Electrical System Specifications341
Front Suspension And Steering343
Front Wheel Removal/Installation343
Front Hub344
Front Strut Cartridge And Spring344
Front Strut/Spindle Removal/Installation350
Ball Joint Inspection/Replacement352
Control Arm353
Handlebar Removal355
Handlebar Installation356
Tie Rods Removal357
Steering Shaft Removal/Installation362
Tire Changing363
Rear Wheels Removal/Installation368
Tire Changing And Tire Repairs369
Shock Absorber369
Shock Inspection370
Spring Removal/Installation370
Rear Hub And Bearing Carrier371
Rear Axle Bearing Carrier Bearing Replacement376
Rear Axles377
Upper Control Arm381
Lower Control Arm381
Upper And Lower Control Arm Inspection383
Stabilizer Linkage384
Stabilizer Support385
Rear Suspension Specifications387
Rear Suspension Torque Specifications387
Disc Brakes388
Brake Service388
Front Brake Pad Replacement389
Front Brake Caliper390
Front Caliper Removal/Installation393
Front Caliper Disassembly394
Output Shaft Brake Caliper400
Output Shaft Brake Pad Replacement403
Front Master Cylinder Removal/Installation410
Front Caliper Brake Hoses420
Output Shaft Caliper Brake Hoses420
Rear Brake Pedal421
Rear Brake Lever423
Foot Brake423
Bleeding The System426
Brake Bleeder Process426
Without A Brake Bleeder428