Notes, Cautions And Warnings; Safety First - Polaris 1999 Sportsman 400 Service Manual

2
ical sy mptoms and logi cal method s to pinpoin t the
trouble.
C ha pter Th ree ex p lains all pe rio di c lubrication
and rou tine maint enan ce necessary to keep the vehi-
cle funn ing wel l. Cha pter Three also incl udes rec-
o mm en ded
t UIl C-Up
procedu res , el imina ting the
need to co nst ant ly co nsu lt chapte rs o n the variou s
ass emb lies .
Subsequent chapters describe s pecific sys te ms
suc h as the engi ne , clutch/drive belt sy stem, tran s-
missio n, exhaust, coo ling, suspens ion and brakes.
Each chapter pro vid es d isas sembly, repair an d as-
sem bly p rocedures in a simp le s tep- by-step form .
Ifa repair is impract ica l for a ho me mechanic.
it
is
so indicated. It is usuall y faster ami less expensive
to take such repairs to a dealer or com petent repair
shop. Spec ifications conc ern ing a particul ar system
arc included at the end of th e app ro priate chap ter.
So me of the proced ures in thi s manual spec ify
special too ls. In most cases, the too l is illustrated ei-
th er
in
actua l use or alone. We ll-e q uipped mec han-
ic s m ay find they ca n subs titute sim ilar too ls
already on ha nd or ca n
fabricate
thei r own.
NOTES, CAUTIONS AND WARNINGS
T he terms NOT E, CA UT IO N an d WARNING
have specific mean ings in this ma nual. A NOTE
pro vides add itio na l in form ation to make a step or
procedure eas ie r o r clearer. Disregardi ng
a NOTE
could cause incon venien ce, bu t wou ld not ca use
eq uipment damage or personal injury.
A CAUTION empha s ize, areas w here eq uipme nt
da mage co uld result. Disregard ing a CA UT ION
co uld cause permanent mechanica l damage ; hO\\I-
ever, p ersonal inju ry is unli kely.
A WARN ING emp hasi ze s area s where pe rsonal
injury
or eve n death co uld resu lt fro m ne glige nce.
M ec ha n ica l da m age may also occur. WARNI NG S
are
fa
be take n serio usly.
In some cases , serious in-
j ut)' or death has resu lted from d isregarding s imilar
w arn ings .
SA rETY FIRST
Pro fessional mechan ics can wo rk for ye ars and
never sustain a se rio us inj ury. I
f
a few rul es o f co m-
mon sense and safe ty arc ob served. many safe hours
can be enjoye d serv ic ing the ATY. Ign or ing these
CHAPTER ONE
rul es ca n inj ure so meo ne wor king on the ve h icle. o r
dam age the AT V.
I. Never
lise gaso line o r any type o f low flash po int
so lve nt to clean pa rts, Se c
Cleaning Parts
and
Han-
dling Gasoline Safet y
in this chapter for add itional
informat ion on parts c lea ning, ga so line usc and
safety.
NOTE
The
flash
point is the lowest tempera-
lure a t
which the
vaporsfrom
a co m-
bustible liquid will ign ite when in
open ail: A lowjlash po int solve nt will
ignite at a lower temperature than a
higlzjlash point solvent.
2. Never
smo ke or usc a to rch in the vici nity o f
flammable liquids in ope n co ntai ners, suc h as gaso-
line or clean ing so lve nt.
3. lf
wc lding o r bra zin g is req uir ed on
the
vehicle.
re move the fue l rank , carburetor, and fron t and rea r
shoc ks to a safe d istance at leas t 50 feet ( 15 m)
awa y.
4. Use the pro per s ized wre nc hes to avo id damage
to fa steners.
5. Wh en loose ning a tight or stuck nut , be gui de d
by wha t wou ld happen if th e wrench slips.
6.
W he n rep lacing
a
fa sten er, mak e su re to
usc
one
wi th the sa me measu rem ents and streng th as the o ld
one. Inco rrect or m ism atch ed fasteners can result in
da mage to th e ve hicle and possibl e personal inj ury.
Beware of faste ne r kits that are fill ed w ith chea p
and poorly mad e nut s. bolt s, washe rs and co tte r
pins. Refer to Faste ne rs in thi s ch apt er for add i-
tion al
inform ation.
7. Keep all hand and po wer tool s in go od condition.
W ipe greas y and o ily too ls after us ing the m. Dirty
too ls arc d iffi c ult to ho ld and can cause injury. Re-
place
o r repair
worn or
damaged
tools.
8. Kee p the work area c lea n and uncl uttered.
9 . Wear safety g ogg lcs during all operations in-
vo lving drilling , g r ind ing. th e use o f a co ld chisel,
usin g che m ica ls, c lea ning parts, wh en using co m-
pressed air or
anytim e
the sa fe ty o f eyes is in-
vo lved.
10 . Mak e su re to we ar th e correct typ e of clothes
for th e job. Long hair should be tied u p or covered
wit h a ca p so thai it canno t be caug ht
by
a pie ce of
mo vin g eq uipme nt or too l.