Polaris Sportsman 400 H.O. Manuals

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

Polaris Sportsman 400 H.O. Service Manual (432 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 21.92 MB

General Information Chapter 1 1

4
- General
  4
  - Table of Contents
    4
  - Chapter 1 Model Number
    5
- General Information
  5
- Model Number Information
  5
- Vehicle Identification Number (Vin)1.2
  5
- Vehicle Specifications
  7
- Misc. Numbers/Charts
  15
  - Conversion Table
    15
  - Standard Bolt Torque Specification
    16
  - Metric Bolt Torque Specification
    16
  - Metric Tap Drill Sizes
    17
  - Paint Codes
    18
  - Replacement Keys
    18
  - Glossary of Terms
    19
Maintenance Chapter 2 Maintenance 2

20
- Maintenance
  23
- Chapter 2 Periodic Maintenance Chart
  25
- Lubricants / Service Products
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
- Lubrication / Fluids
  26
  - Pre-Ride / Daily Inspection
    26
  - Lubrication Components
    27
  - Front Gearcase Lubrication
    28
  - Transmission Lubrication
    29
- Adc System (if Equipped)
  30
  - Adc System Fluid Reservoir Location
    30
  - Adc Differential Hydraulic Circuit Fluid Change
    30
- Vehicle Inspection
  31
  - Shift Link Rod Inspection
    31
  - Throttle Inspection
    31
  - Throttle Cable / Electronic Throttle Control Adjustment
    32
  - Fuel System
    32
  - Fuel Lines
    33
  - Vent Lines
    33
  - Choke (Enricher) Adjustment - (500 Carb)
    33
  - Compression Test
    33
  - Engine Mounts
    33
  - Spark Plug
    34
  - Battery Maintenance
    34
  - Liquid Cooling System Overview
    35
  - Coolant Strength / Type
    35
  - Cooling System Hoses
    35
  - Radiator/Grill Screen
    36
  - Cooling System Pressure Test
    36
  - Coolant Level Inspection
    36
  - Radiator Coolant Level
    37
  - Air Filter/Pre-Filter Service
    38
  - Air Box Sediment Tube
    39
  - Breather Filter Inspection
    39
  - Breather Hose
    39
  - Recoil Housing
    39
  - Engine Oil Level
    40
  - Oil and Filter Change
    40
  - Oil Pump Priming Procedure
    42
  - Valve Clearance
    42
  - Intake Valve Clearance Adjustment
    43
  - Exhaust Valve Clearance Adjustment
    43
  - Steering
    43
    
    Final Drive
    44
  - Tie Rod End/Steering Inspection
    44
  - Camber and Caster
    44
  - Wheel Alignment
    44
  - Toe Alignment Adjustment
    45
  - Exhaust Pipe
    45
  - Brake System Inspection
    46
  - Brake Pad Inspection
    47
  - Hose/Fitting Inspection
    47
  - Auxiliary Brake Testing
    47
  - Auxiliary Brake Adjustment (Hydraulic)
    48
  - Suspension Spring
    48
- Preload Adjustment
  48
  - Front Suspension
    48
  - CV Shaft Boot Inspection
    48
  - Controls
    49
  - Wheels
    49
  - Wheel, Hub, and Spindle
    49
  - Torque Table2.30
    49
  - Wheel Removal Front or Rear
    50
  - Wheel Installation
    50
  - Tire Pressure
    50
  - Tire Inspection
    51
  - Frame, Nuts, Bolts, Fasteners
    51
- Carburetor Maintenance
  51
  - Choke (Enricher) Adjustment (Non Efi)
    51
  - Pilot Screw
    51
  - Pilot Screw Adjustment
    52
  - Idle Speed Adjustment (Non Efi)
    53
  - Fuel Filter (Non Efi)
    53
  - Carburetor Draining
    54
  - Maintenance Schedule
    55
Chapter 3 Engine

56
- Engine Fastener Torque Patterns
  58
- Specifications
  58
- Torque Specifications
  58
- Sportsman 500 H.o. Engine Service Data
  59
- Sportsman 400 H.o. Engine Service Data
  61
- General Engine Service
  63
  - Cooling System Specifications
    63
  - Cooling System
    64
  - Accessible Components
    65
  - Engine Removal
    65
  - Engine Installation Notes
    67
  - Cylinder Hone Selection/ Honing Procedure
    67
    
    Electrical
    68
  - Honing to Oversize
    68
  - Cleaning the Cylinder after Honing
    68
  - Crankshaft Straightening
    69
  - Engine Lubrication
    69
  - Oil Pressure Test
    69
  - Oil Flow
    70
  - Oil Flow Diagram
    71
  - Engine Exploded Views
    72
- Special Tools
  63
- Engine Disassembly
  73
  - Cam Chain Tensioner / Rocker Arm /Camshaft Removal
    73
  - Cam Chain Tensioner Inspection
    73
  - Rocker Arm / Shaft Inspection
    74
  - Camshaft Removal
    75
  - Automatic Compression Release Removal / Inspection
    76
  - Automatic Compression Release Installation
    76
  - Camshaft Inspection
    77
  - Cylinder Head Removal
    77
  - Cylinder Head Exploded View
    78
  - Cylinder Head Inspection
    79
  - Cylinder Head Warpage
    79
  - Cylinder Head Disassembly
    79
  - Valve Inspection
    80
  - Combustion Chamber
    81
  - Valve Seat Reconditioning
    81
  - Cylinder Head Assembly
    84
  - Valve Sealing Test
    84
  - Valve Clearance Adjustment
    84
  - Cylinder / Piston Removal and Inspection
    85
  - Piston Removal
    86
  - Cylinder Inspection
    87
  - Cylinder Hone Selection / Honing Procedure
    87
  - Honing to Oversize
    88
  - Cleaning the Cylinder after Honing
    88
  - Piston-To-Cylinder Clearance
    89
  - Piston / Rod Inspection
    89
  - Piston Identification
    90
  - Piston Ring Installed Gap
    90
  - Crankcase Disassembly
    91
  - Starter Drive Removal / Inspection
    91
  - Flywheel and Stator Removal / Inspection
    91
  - Cam Chain / Tensioner Blade
    92
  - One Way Valve
    93
  - Crankcase Separation
    93
  - Oil Pump Removal / Inspection
    93
  - Oil Pump Assembly
    95
  - Counter Balancer Shaft Removal / Inspection
    95
  - Crankshaft Removal / Inspection
    96
  - Crankcase Bearing Inspection
    97
  - Oil Seal / Mechanical Seal Removal (Engine Disassembled)
    97
  - Crankcase Inspection
    97
  - Bearing Installation
    98
  - End Play Inspection / Adjustment
    98
  - Crankshaft End Play Adjustment
    98
  - Counter Balancer Shaft End Play Adjustment
    99
  - Oil Pump Shaft End Play Adjustment
    100
- Engine Reassembly
  100
  - Pump Shaft Oil Seal Installation
    100
  - Crankshaft / Counter Balance / Oil Pump Installation
    100
  - Crankcase Assembly
    101
  - Water Pump Mechanical Seal Installation
    101
  - Water Pump Mechanical Seal Removal (Engine Installed)
    102
  - One Way Valve Installation
    103
  - Cam Chain Drive Sprocket Installation
    103
  - Tensioner Blade Installation
    103
  - Piston Ring Installation
    103
  - Piston Installation
    104
  - Cylinder Installation
    104
  - Cylinder Head Installation
    105
  - Cam Chain / Camshaft Installation
    106
  - Camshaft Timing
    106
  - Camshaft Timing Illustration
    108
  - Cam Chain Tensioner Installation
    109
  - Stator, Flywheel and Starter Drive Installation
    109
  - Rocker Shaft / Rocker Arm Assembly Installation
    110
  - Thermostat Installation
    110
  - Oil Pipes
    110
  - Oil Pump Priming Procedure
    110
- Recoil (Accessory)
  111
- Troubleshooting
  113
Carburation and Fuel System Chapter 4 Carburation and Fuel System

118
- Carburetor Jetting
  119
- Chapter 4
  119
- General Information and Specifications
  119
- Mikuni Jet Part Numbers
  119
- Special Tools
  119
- Carburetion
  120
  - Bst 40 Carburetor Exploded View 1 of 2
    120
  - Bst 40 Carburetor Exploded View 2 of 2
    121
  - CV Carburetor System Function
    122
  - Mikuni CV Carb Operation
    122
  - Carburetor Venting
    123
  - Starter System (Choke or Enrichment)
    123
  - Pilot (Idle and Slow) System
    124
  - Main System
    124
  - Float System
    125
  - Pilot Screw
    125
  - Air/Fuel Mixture Ratio
    126
  - Jet Needle
    126
  - Needle Jet
    126
  - Throttle Opening Vs. Fuel Flow
    127
  - Carburetor Disassembly - Mikuni CV
    127
  - Carburetor Cleaning
    128
  - Carburetor Inspection
    128
  - Carburetor Assembly
    129
  - Float Height Adjustment
    129
  - Needle and Seat Leakage Test
    130
  - Fuel Level Test
    130
- Carbutated Fuel Tank / Fuel Delivery System
  131
- Fuel Gauge Sending Unit Test
  132
- Fuel Pump (Carburated)
  132
- Fuel Pick-Up / Sending Unit Replacement (Carb.)
  133
- Fuel Tank Vent Routing (Non Intl)
  136
- 500 H.o. International Emissions System
  137
- Troubleshooting
  138
Carburation and Fuel System Notes

140
- Special Tools
  142
- 500 Efi Tractor Speed Control
  144
  - System Operation Overview
    144
  - Air Control Body Removal and Disassembly
    145
  - Air Control Body Assembly and Installation
    145
  - Air Solenoid Valve Test / Replacement
    145
  - Exhaust System
    146
- Efi Service Notes
  147
- Efi System Exploded View
  148
- Efi System
  149
  - Component Locations/Identification
    149
- Fuel System and Fuel Tank
  151
  - Fuel System and Fuel Tank Exploded View
    151
- Electronic Fuel Injection
  152
  - General Information
    152
  - Efi Operation Overview
    152
  - Initial Priming / Starting Procedure
    152
- Electronic Control Unit (Ecu)
  153
  - Operation Overview
    153
  - Ecu Replacement
    154
  - Ecu Service
    154
- Fuel Lines
  153
  - Quick Connect Removal/Installation
    153
- Fuel Pump Assembly
  155
  - Operation / Testing
    155
  - Fuel Pump Test
    155
  - Fuel Tank Replacement
    156
  - Fuel Sending Unit Test
    157
  - Fuel Pump Replacement
    158
- Fuel Filter
  161
- Fuel Injector
  161
- Fuel Pressure Regulator
  161
- Crankshaft Position Sensor (Cps)
  163
- Manifold Air Pressure Sensor (Map)
  164
  - Operation Overview
    164
  - Map Sensor Test
    164
  - Map Sensor Replacement
    164
- Idle Air Control (Iac)
  165
- Intake Air Temperature Sensor (Iat)
  165
- Throttle Position Sensor (Tps)
  166
  - Operation Overview
    166
  - Throttle Position Sensor Test
    166
  - Throttle Position Sensor Replacement
    168
  - Throttle Position Sensor Initialization
    168
- Engine Temperature Sensor
  169
  - General Information
    169
  - Engine Temperature Sensor Test
    169
  - Engine Temperature Sensor Replacement
    169
- Fuel System Troubleshooting
  170
  - Fuel Starvation / Lean Mixture
    170
- Efi Diagnostics Using 'Blink Codes
  171
  - Blink Codes - Operation
    171
- Digital Wrench™ Operation
  172
- Troubleshooting Diagrams
  180
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

186
- Chapter 5
  187
- Decal Replacement
  187
- General Information
  187
- Special Tools
  187
- Torque Specifications
  187
- Plastic Insert Removal / Installation
  188
- Body
  189
  - Side Panel Removal
    189
  - Foot Well Removal / Installation
    190
  - Front Bumper Removal / Installation
    191
  - Mud Guard Removal / Installation
    191
  - Front Fender Removal/Installation
    192
  - Front Rack / Storage Box Lid Assembly
    193
  - Front Cab Assembly
    194
  - Front Bumper Assembly
    195
  - Rear Rack Assembly
    196
  - Rear Cab and Seat Assembly
    197
  - Rear Storage Box Assembly
    198
  - Winch and Front Bumper Mounting
    199
  - Headlight Pod Exploded View
    200
- 500 Efi Tractor Seat Assembly
  201
  - Overview
    201
  - Seat Dampener Repair
    201
  - Seat Pivot Repair
    201
  - 500 EFI Tractor Seat Assembly Exploded View
    202
- 500 Efi Tractor Steering Post and Lock
  203
  - Steering Assembly Exploded View
    203
- Steering
  204
  - Handlebar Block Installation Procedure
    204
  - Steering / A-Arm Exploded View
    205
  - A-Arm Replacement
    206
  - Ball Joint Replacement
    207
  - Steering Post Removal
    208
  - Steering Post Assembly
    208
- Suspension
  208
  - Front Strut Cartridge Replacement
    208
  - Strut Assembly
    209
  - Sportsman Rear Suspension Assembly
    210
  - Torsion Bar Exploded View
    211
Chapter 6 Clutching

213
- General Operation
  214
- Pvt System Overview
  214
- Special Tool and Supplies
  214
- Torque Specifications
  214
- Drive Clutch Operation
  215
- Driven Clutch Operation
  215
- Clutching Chart
  216
- Maintenance / Inspection
  216
- Pvt Break-In (Drive Belt / Clutches)
  216
- Overheating / Diagnosis
  217
- Pvt Exploded Views
  218
- Pvt System Service
  219
  - Disassembly
    219
  - Assembly
    220
- Drive Belt
  221
  - Belt Removal
    221
  - Belt Inspection
    222
  - Belt Installation
    222
  - Pvt Break-In (Drive Belt / Clutches)
    222
- Clutch Alignment
  222
- Clutch Center Distance
  224
- Drive Clutch Service (Non Ebs)
  225
  - Exploded View (Non Ebs)
    225
  - Clutch Disassembly
    226
  - Drive Clutch Spring Inspection
    227
  - Shift Weight Inspection
    227
  - Spider Removal
    228
  - Button to Tower Clearance Inspection
    229
  - Shift Weight Inspection
    229
  - Bearing Inspection
    230
  - Clutch Inspection
    230
  - Moveable Sheave Bushing Inspection
    231
  - Clutch Assembly
    232
- Ebs Drive Clutch Service
  233
  - Ebs Drive Clutch Exploded View
    233
  - Drive Clutch Disassembly
    233
  - Spider Removal
    234
  - Button to Tower Clearance Inspection
    235
  - Shift Weight Inspection
    235
  - Drive Clutch Inspection
    236
  - Moveable Sheave Bushing Inspection
    237
  - One-Way Clutch Inspection (Ebs Drive Clutch)
    237
  - Drive Clutch Reassembly
    238
- Drive Clutch Bushing Service (Non Ebs and Ebs)
  239
- Non Ebs Driven Clutch
  242
- Driven Clutch Service (Ebs)
  247
- Driven Clutch Bushing Service
  254
- Troubleshooting
  256
Chapter 7 Final Drive

259
- Gearcase Fluid / Capacity
  260
- Special Tools
  260
- Specifications
  260
- Torque Table
  260
- Front Hub
  261
  - Disassembly
    261
  - Assembly
    261
- Front Gearcase Removal and Installiation (Adc and Non Adc)
  262
  - Gearcase Removal
    262
  - Gearcase Installation
    263
- Front Gearcase - Centralized Hilliard Non Adc (4X4)
  264
  - Operation Non Adc
    266
  - Disassembly / Inspection Non Adc
    267
  - Reassembly / Inspection Non Adc
    270
  - Front Gearcase Diagnosis
    272
  - Setting Ring Gear Backlash Non Adc
    274
- Front Gearcase - Centralized Hilliard Adc
  275
  - Operation
    275
  - Adc Gearcase Exploded View
    276
  - Adc Operation
    277
  - Front Gearcase Diagnosis
    278
  - Coil Testing
    279
  - Adc Differential Hydraulic Circuit Bleeding
    279
  - Disassembly / Inspection
    280
  - Adc Gearcase Piston Replacement Procedure
    284
  - Assembly
    285
  - Setting Ring Gear Backlash
    288
- Front Drive (CV) Shaft
  289
  - Inspection
    289
  - Removal
    289
  - Installation
    291
- Rear Hub
  292
  - Removal
    292
  - Disassembly
    293
  - Assembly
    294
  - Installation
    294
- Rear Drive (CV) Shaft
  295
  - Inspection
    295
  - Removal
    295
  - Installation
    296
- CV Drive Shaft Service
  297
- Prop Shaft - Front or Rear
  304
  - Removal and Installation
    304
- U-Joint Service
  305
  - Disassembly
    305
  - Assembly
    306
Transmission Chapter 8 Transmission

307
- Chapter 8
  308
- Lubrication
  308
- Special Tools
  308
- Torque Specifications
  308
- Transmission - General
  308
- Transmission Frame Mounts
  309
- Transmission Upper Frame Mount
  310
- Transmission Rear Stabilizer Mounts
  311
- Transmission Control Arm Bracket Mounts
  312
- Gear Selector Removal
  313
- Shift Linkage Inspection
  313
- Transmission Removal
  313
- Transmission Installation
  314
- Troubleshooting Checklist
  314
- 2012 Sportsman Transmission Exploded View
  315
- Transmission Disassembly / Assembly
  317
  - Transmission Disassembly
    317
  - Snorkel / Output Gear Backlash Procedure
    322
  - Transmission Assembly
    325
Brakes Chapter 9 Brakes

331
- Chapter 9
  332
- Component Service Limits
  332
- Specifications
  332
- Torque Table
  332
- Hydraulic Brake System
  333
  - Operation Overview
    333
  - Overview: Sportsman Forest 500 (Intl A12Mh50Ff)
    334
  - Brake Noise Troubleshooting
    334
  - Brake Bleeding / Fluid Change
    335
- Special Tools
  333
- Brake System Exploded Views
  337
  - Sportsman Touring 500 Ho Component Exploded View
    337
- Brake Caliper Exploded Views
  340
  - Sportsman 500 Ho Touring Rear Caliper Assembly (Non Intl.)
    340
  - Sportsman Forest 500 (Intl.) Front Caliper Assembly
    341
- Front Master Cylinder All Models
  342
  - Removal
    342
  - Installation
    342
- Front Brakes
  343
  - Pad Removal
    343
  - Assembly
    344
  - Brake Burnishing Procedure
    345
- Front Brake Disc
  345
- Front Caliper
  347
  - Removal
    347
  - Inspection
    348
  - Reassembly
    348
  - Installation
    349
- Rear Brake Pad
  350
  - Touring Pad Removal
    350
  - Touring Pad Installation
    351
  - Sportsman Rear Pad Removal
    352
  - Sportsman Rear Pad Installation
    353
  - Brake Burnishing Procedure
    353
- Touring Rear Caliper
  354
  - Removal
    354
  - Inspection
    355
  - Reassembly
    355
- Sportsman Rear Caliper
  356
  - Removal and Inspection
    356
  - Assembly
    357
- Rear Brake Disc
  359
- Rear Master Cylinder
  360
- Troubleshooting
  364
Chapter 10 Electrical

365
- General Information
  367
- Ignition System / Basic Electrical Components
  367
- Special Tools
  367
- Electrical Service Notes
  368
- Troubleshooting
  368
- Instrument Cluster
  369
  - Overview
    369
  - Instrument Cluster Diagnostic Mode
    371
  - Setting a New Service Interval
    373
  - Efi Diagnostic Mode
    374
  - Speedometer Removal
    375
  - Speedometer Installation
    375
- All Wheel Drive and Speedometer Troubleshooting
  376
- All Wheel Drive (Awd) Coil
  381
  - Operation Overview
    381
  - Diagnosing System Failures
    381
- Cooling System Components
  381
  - Fan Control Circuit Operation
    381
  - Fan Control Bypass Test - Efi
    381
  - Fan Control Bypass Test - H.o
    381
  - Fan Motor Current Draw Test
    382
  - Coolant Temperature Sensor - Efi
    382
  - Coolant Temperature Fan Switch - H.o
    383
- Gear Position Indicator Switch
  383
  - Test Diagram
    383
- Electronic Throttle Control (Etc) Switch
  384
  - Operation Overview
    384
  - Etc Test
    384
- Ignition System
  385
  - Overview
    385
  - Components of Alternator and DC / CDI Ignition System
    386
  - Efi Ignition System Testing Flow Chart
    387
  - Crankshaft Position Sensor Gap
    387
  - Ignition Troubleshooting
    388
  - Ignition Output Test Using Gap Tester
    388
- Charging System
  388
  - Current Draw - Key off
    388
  - Break Even Test
    389
  - Charging System Testing Diagrams
    391
- Relays
  393
- Fuses/Circuit Breaker
  394
- Lighting
  394
  - High Beam Headlight Bulb Replacement
    394
  - Headlight Housing Replacement
    395
  - High Beam Headlight Adjustment
    396
  - Lower Headlamp Removal / Installation
    396
  - Low Beam Headlight Adjustment (Non Intl)
    397
  - Lower Headlight Adjustment (Forest Tractor)
    398
  - Headlamp Switch Test
    398
  - Brake Light Replacement
    399
  - Brake Light Switch
    399
- Fuel Sender
  400
- Speed Sensor
  400
- Accessory Power
  401
- Starter System
  401
  - Troubleshooting
    401
  - Voltage Drop Test
    402
  - Starter Lockout Troubleshooting- Efi
    402
  - Starter Lockout Troubleshooting- H.o
    402
  - Starter Lockout Diagram- Efi
    403
  - Starter Lockout Diagram- Carb
    403
  - Starter Motor Removal / Disassembly
    404
  - Brush Inspection / Replacement
    404
  - Armature Testing
    405
  - Starter Solenoid Bench Test
    406
  - Starter Exploded View
    406
- Starter Drive
  407
- Starter System Testing Flow Chart
  408
- Battery
  409
  - Battery Identification
    409
  - Battery Conductance Analyzer
    409
  - Battery Activation (Conventional)
    410
  - Battery Terminals/Bolts
    410
  - Conventional Battery Inspection / Removal
    411
  - Conventional Battery Installation
    411
  - Conventional Battery Testing
    411
  - Conventional Battery Ocv - Open Circuit Voltage Test
    412
  - Conventional Battery Specific Gravity Test
    412
  - Battery Load Test
    412
  - Off Season Storage
    413
  - Charging Procedure
    413
  - Low Maintenance Battery
    414
  - Low Maintenance Battery Charging
    415
  - Low Maintenance Battery Inspection / Removal
    415
  - Low Maintenance Battery Installation
    415
  - Low Maintenance Battery - Ocv- Open Circuit Voltage Test
    416
  - Low Maintenance Battery Load Test
    416
  - Low Maintenance Battery Charging Procedure
    417
  - Low Maintenance Battery Off-Season Storage
    417
- Troubleshooting Diagrams
  418
- Sportsman 500 Efi Forest Tractor Electrical
  420

Polaris Sportsman 400 H.O. Owner's Manual (137 pages)

Polaris Industries All-Terrain Vehicles Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 5.73 MB

Table of Contents
7
Introduction
8
Vehicle Identification Numbers
10
Safety
11
- Equipment Modifications
  13
- Eye Protection
  13
  - Age Restrictions
    14
  - Operating Without Instruction
    14
  - Safety Warnings
    14
  - Exposure to Exhaust
    15
  - Handling Gasoline
    15
  - Carrying a Passenger
    16
  - Protective Apparel
    16
  - Operating on Pavement
    17
  - Operating on Public Roads
    17
  - Improper Hill Climbing
    18
  - Jumps and Stunts
    18
  - Physical Control of the Atv
    18
  - Turning Improperly
    18
  - Crossing Hillsides
    19
  - Descending Hills Improperly
    19
  - Operating on Steep Hills
    20
  - Stalling While Climbing a Hill
    20
  - Operating in Unfamiliar Terrain
    21
  - Operating on Slippery Terrain
    21
  - Skidding or Sliding
    22
  - Improper Cargo Loading
    23
  - Operating through Deep Water
    23
  - Hot Exhaust Systems
    24
  - Operating a Damaged Atv
    24
  - Physical Skills
    24
  - Poor Visibility
    24
  - Unauthorized Use of the Atv
    24
  - Safety Decals and Locations
    25
  - Age 16 Warning
    26
  - No Passenger" Warning
    26
  - Tire Pressure/Load Warning
    26
  - Clutch Cover Warning
    27
  - Rack Warning, Front and Rear
    27
- Awd Switch
  28
- Mode/Reverse Override Switch
  28
Features and Controls
28
- Engine Stop Switch
  29
- Headlight Switch
  29
- Main Key Switch
  29
- Brake Lever
  31
- Parking Brake
  33
- Fuel Filter
  35
- Fuel Valve
  35
- All Wheel Drive System
  37
- Engaging Awd
  37
- Instrument Cluster
  39
- Rider Information Center
  39
Operation
45
- Break-In Period
  45
  - Safe Operation Practices
    47
  - Trail Etiquette
    48
  - Pre-Ride Checklist
    49
  - Starting the Engine
    50
  - Cold Weather Operation
    51
  - Turning the Vehicle
    53
- Driving on Slippery Surfaces
  54
- Driving Uphill
  55
- Driving Downhill
  57
- Driving through Water
  59
- Driving over Obstacles
  60
- Driving in Reverse
  61
  - Hauling Cargo
    62
  - Towing Loads
    63
  - Parking on an Incline
    64
- Crankcase Emission Control System
  65
- Electromagnetic Interference
  65
- Exhaust Emission Control System
  65
- Noise Emission Control System
  65
Emission Control Systems
65
Periodic Maintenance Chart
66
Maintenance
66
- Periodic Maintenance Chart
  68
- Lubrication Guide
  71
- Engine Oil
  72
  - Oil Recommendations
    72
  - Oil Level
    73
  - Oil and Filter Change
    74
  - Oil Pump Priming
    76
  - Oil Check
    77
  - Transmission Oil
    77
  - Oil Change
    78
- Fluid Change
  79
- Cooling System
  80
  - Recovery Bottle Coolant
    80
  - Radiator Coolant
    81
  - Hand Brake
    82
  - Toe Alignment
    83
- Footwell Removal
  84
  - Side Panel Removal
    84
  - Steering Assembly
    84
  - Tire Tread Depth
    85
  - Wheel Removal
    85
  - Wheel Installation
    86
  - Wheel Nut Torque Specifications
    86
- Air Filter
  87
  - Fuse Replacement
    89
  - Headlight Lamp Replacement
    90
  - High Beam Adjustment
    91
  - Headlight Housing Replacement
    92
  - Lower Headlamp Replacement
    93
  - Spark Plug Inspection
    94
  - Spark Plug Recommendations
    94
  - Spark Plugs
    94
  - Vehicle Immersion
    96
  - Spark Arrestor
    97
  - Pvt System
    98
  - Pvt Drying
    100
  - Battery Removal
    102
  - Battery Installation
    103
  - Battery Storage
    104
  - Camber and Caster
    107
  - Rear Spring
    107
  - Carburetor/Engine Idle Rpm Adjustment
    108
  - Throttle Cable Freeplay
    109
- Cleaning and Storage
  110
- Polishing the Vehicle
  111
- Storage Tips
  113
- Transporting the Atv
  116
Troubleshooting
117
- Drive Belt Wear/Burn
  117
Engine Overheating
120
Polaris Products
121
Specifications
122
- Clutching Chart
  123
- Jetting Chart
  123
Declaration of Conformity
124
Limited Warranty
125
Warranty
125
Maintenance Log
133
Maintenance Log
134
Index
135
Index
136
Specifications
137

Polaris Sportsman 400 H.O. Owner's Manual (135 pages)

Polaris Industries 2008 All-Terrain Vehicle Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 1.95 MB

Table of Contents
3
Know Your Vehicle
5
Safety
6
- Safety Decals and Locations
  7
- Discretionary Warning
  7
- Age 16 Warning
  8
- Reverse Override Warning
  9
- All Wheel Drive Switch
  9
- Hitch Capacity Label
  9
- Safe Riding Gear
  10
- Eye Protection
  11
- Operator Safety
  12
- Safety Training
  13
- Equipment Modifications
  18
Features and Controls
34
- Engine Stop Switch
  35
- Headlight Switch
  35
- Throttle Lever
  36
- Brake Lever
  37
- Parking Brake
  38
- Fuel Valve
  40
- Fuel Tank Cap, Valve & Filter
  40
- Fuel Filter
  40
- Recoil Starter
  42
- Engaging Awd
  43
- Instrument Cluster
  44
- Rider Information Center
  45
Operation
46
- Starting the Engine
  50
- Cold Weather Operation
  51
- Hauling Cargo
  52
- Driving Safely
  54
- Turning the Vehicle
  55
- Driving on Slippery Surfaces
  56
- Driving Uphill
  57
- Driving Downhill
  59
- Driving through Water
  62
- Driving over Obstacles
  64
- Driving in Reverse
  65
Emission Control Systems
67
Maintenance
68
- Maintenance Chart Key
  69
- Periodic Maintenance Chart
  69
- Lubrication Guide
  73
- Engine Oil
  74
- Oil Recommendations
  74
- Engine Oil Level
  75
- Oil and Filter Change
  76
- Transmission Oil
  78
- Oil Change
  80
- Fluid Change
  83
- Cooling System
  84
- Recovery Bottle Coolant
  84
- Radiator Coolant
  85
- Brake Fluid
  86
- Hand Brake
  87
- Foot Brake
  87
- Brake Inspections
  88
- Toe Alignment
  89
- Side Panel Removal
  90
- Tire Tread Depth
  91
- Front Wheel Hub Tightening
  91
- Wheel Removal
  92
- Wheel Installation
  93
- Air Filter
  94
- Headlight Beam Adjustment
  95
- Headlamp Replacement
  96
- Recoil Housing
  97
- Spark Plugs
  98
- Spark Plug Inspection
  98
- Spark Plug Condition
  99
- Vehicle Immersion
  100
- Spark Arrestor
  101
- Pvt System
  102
- Pvt Drying
  103
- Battery Maintenance
  104
- Conventional Battery
  104
- Battery Removal
  105
- Battery Installation
  106
- Battery Storage
  107
- Cleaning and Storage
  110
- Washing the Vehicle
  111
- Polishing the Vehicle
  111
- Storage Tips
  113
- Transporting the Vehicle
  116
Adjustments
117
Throttle Cable Freeplay
120
Polaris Products
121
Troubleshooting
122
Engine Overheating
125
Specifications
126
- Jetting Chart
  127
- Clutching Chart
  127
Warranty
128
Maintenance Log
134

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Polaris Sportsman 400 H.O. Manuals

Polaris Sportsman 400 H.O. Service Manual (432 pages)

Table of Contents

General Information Chapter 1 1

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine

Carburation and Fuel System Chapter 4 Carburation and Fuel System

Carburation and Fuel System Notes

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Chapter 6 Clutching

Chapter 7 Final Drive

Transmission Chapter 8 Transmission

Brakes Chapter 9 Brakes

Chapter 10 Electrical

Polaris Sportsman 400 H.O. Owner's Manual (137 pages)

Table of Contents

Polaris Sportsman 400 H.O. Owner's Manual (135 pages)

Table of Contents

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