Polaris Sportsman ATV Workshop Repair Service Manual PDF 400 500 600 700 800 850 XP EFI - MPLRSPORTMAN.zip
A full factory-level service and repair guide, complete with electrical wiring diagrams, for the Polaris Sportsman ATV—packed with everything needed to service, troubleshoot, fix, and rebuild your machine the way a professional technician would.
Inside the Polaris Sportsman ATV workshop service and repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Polaris '01 Sportsman 400_500_H.O._DUSE Service Repair Manual.pdf
Polaris '02-'03 Sportsman 700, 2002 Sportsman 600 Service Repair Manual.pdf
Polaris '02 Sportsman 400-500 MANUAL DE SERVICIO.pdf
Polaris '04 Sportsman 600 Parts Manual.pdf
Polaris '05 Sportsman 400_500 Service Repair Manual.pdf
Polaris '05 Sportsman 400 Parts Manual.pdf
Polaris '05 Sportsman 500 Parts Manual.pdf
Polaris '05 Sportsman 800 Parts Manual.pdf
Polaris '07 Sportsman 450-500 EFI Service Repair Manual.pdf
Polaris '07 Sportsman 700_800_800 X2 EFI Service Repair Manual.pdf
Polaris '07 Sportsman 700 EFI-800 EFI Owner's Manual.pdf
Polaris '08 Sportsman 500 EFI, X2, Touring, 500 H.O. Service Repair Manual.pdf
Polaris '08 Sportsman 500 Service Repair Manual.pdf
Polaris '09 Sportman 300, Sportman 400 H.O. Service Repair Manual.pdf
Polaris '09 Sportman XP 850, XP850 EPS Service Repair Manual.pdf
Polaris '09 Sportsman 6x6 800 EFI Big Boss Service Repair Manual.pdf
Polaris '09 Sportsman 500 Service Repair Manual.pdf
Polaris '09 Sportsman 850_EFI_HD_EPS Service Repair Manual.pdf
Polaris '09 Sportsman XP 550_EPS Service Repair Manual.pdf
Polaris '12-'13 Sportsman 850 Service Repair Manual.pdf
Polaris '96-'03 Sportsman400-500, Xplorer500 Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 6,183 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Polaris '01 Sportsman 400_500_H.O._DUSE Service Repair Manual......1
CHAPTER 1 - GENERAL INFORMATION......2
CHAPTER 2 - MAINTENANCE......28
CHAPTER 3 - ENGINE......69
CHAPTER 4 - FUEL SYSTEM/CARBURETION......150
CHAPTER 5 - BODY AND STEERING......171
CHAPTER 6 - PVT SYSTEM......184
CHAPTER 7 - FINAL DRIVE......232
CHAPTER 8 - TRANSMISSION SERVICE......269
CHAPTER 9 - BRAKES......303
CHAPTER 10 - ELECTRICAL......334
INDEX......373
WIRING DIAGRAM 2001 SPORTSMAN 400......379
WIRING DIAGRAM 2001 SPORTSMAN 500 EARLY......380
WIRING DIAGRAM 2001 SPORTSMAN 500 LATE......381
Polaris '02 Sportsman 400-500 MANUAL DE SERVICIO......382
Polaris '02- '03 Sportsman 700, 2002 Sportsman 600 Service Repair Manual......737
Index......740
Chapter 1 General Information......741
Chapter 2 Maintenance......759
Chapter 3 Engine......789
Chapter 4 Fuel System/Carburetion......847
Chapter 5 Body/Steering/Suspension......859
Chapter 6 PVT System......871
Chapter 7 Final Drive......897
Chapter 8 Transmission Service......925
Chapter 9 Brakes......941
Chapter 10 Electrical......961
Polaris '04 Sportsman 600 Parts Manual......999
Polaris '05 Sportsman 400 Parts Manual......1059
Polaris '05 Sportsman 400_500 Service Repair Manual......1119
INTRODUCTION......1120
TABLE OF CONTENTS......1122
CHAPTER 1-GENERAL......1123
MODEL IDENTIFICATION......1124
SERIAL NUMBER LOCATION......1124
PUBLICATION NUMBERS......1125
PAINT CODES......1125
REPLACEMENT KEYS......1125
GENERAL SPECIFACTIONS -SPORTSMAN 400/500......1126
SPECIAL TOOLS......1129
STANDARD TORQUE SPECIFICATIONS......1135
DECIMAL EQUIVALENT CHART......1136
COVERSION TABLE......1137
GLOSSARY OF TERMS......1138
CHAPTER 2-MAINTENANCE......1139
PERIODIC MAINTENANCE CHART......1140
LUBRICANT AND MAINTENANCE PRODUCT NUMBERS......1144
ATV COMPONENT LOCATIONS......1146
LUBRICATION CHARTS......1147
FRONT GEARCASE LUBRICATION......1148
TRANSMISSION LUBRICATION......1149
LUBRICATIONS POINTS......1150
TRANSMISSION LINKAGE AJUSTMENTS......1151
CARBURETOR/THROTTLE ADJUSTMENTS......1151
FUEL SYSTEM......1154
COMPRESSION TEST......1156
BATTERY MAINTENANCE......1157
COOLANT SYSTEM MAINTENANCE......1157
AIR FILTER SERVICE......1159
AIR BOX SEDIMENT TUBE SERVICE......1160
BREATHER FILTER......1161
RECOIL HOUSING......1161
OIL CHANGE/FILTER......1162
VALVE CLEARANCE......1164
STEERING AND TOE ALIGNMENT......1165
EXHAUST SYSTEM MAINTENANCE......1169
BRAKE SYSTEM SERVICE......1169
SUSPENSION SERVICE......1171
CONTROLS......1171
WHEEL REMOVAL/INSTALATION......1172
TIRE INSPECTION......1172
COMPARTMENT STORAGE......1173
WARN™ WINCH OPERATION......1174
CLEANING AND STORAGE OF ATV......1176
CHAPTER 3-ENGINE......1179
TORUE SPECIFICATIONS......1180
SPECIAL TOOLS......1180
EH50PL SERVICE DATA......1181
TORQUE PATTERNS......1183
PISTON IDENTIFICATION......1183
COOLING SYSTEM PRESSURE TEST......1184
COOLING SYSTEM SPECIFICATIONS......1185
ENGINE REMOVAL......1185
ENGINE INSTALLATION NOTES......1186
CYLINDER HONEING......1186
CRANKSHAFT RUNOUT INSPECTION......1187
EH50PL ENGINE LUBRICATION......1188
EH50PL OIL PUMP PRIMING PROCEDURE......1188
EH50PL LUBRICATION/OIL FLOW......1189
EH50PL ENGINE EXPLODED VIEW......1191
EH50PL ENGINE TOP END DISASSEMBLY......1192
EH50PL VALVE SEAT SERVICE......1201
EH50PL CYLINDER HEAD ASSEMBLY......1204
EH50PL ENGINE BOTTOM END DISASSEMBLY......1209
EH50PL CRANKCASE & BEARING ASSEMBLY......1215
EH50PL CRANKSHAFT END PLAY INSPECTION......1216
EH50PL COUNTER BALANCER SHAFT END PLAY INSPECTION......1218
EH50PL OIL PUMP SHAFT END PLAY INSPECTION......1218
EH50PL ENGINE ASSEMBLY/INSPECTION......1219
SEALED RECOIL DISASSEMBLY/INSPECTION......1229
SEALED RECOIL ASSEMBLY......1230
SPARK PLUG FOULING CHECKLIST......1231
TROUBLESHOOTING......1231
CHAPTER 4-FUEL/CARBURETION ......1233
EXPLODED VIEW, MIKUNI BST 34/40 CARBURETOR......1234
FUEL TANK ASM. EXPLODED VEIW......1236
FUEL FLOW DIAGRAM......1236
FUEL COMPONENT OVERVIEW......1237
FUEL SENDER REMOVAL/INSTALL......1237
SPECIAL TOOL & JETTING GUIDELINES......1238
CARBURETOR JETTING......1239
MAIN JET/PILOT JET PART NUMBERS......1239
CV CARBURETOR SYSTEM FUNCTION (4 CYCLE)......1240
CV CARBURETOR VENT SYSTEM (4 CYCLE)......1238
CV CARBURETOR OPERATION......1240
PILOT SCREW INFORMATION......1242
DISASSEMBLY NOTES, CV CARBURETOR......1243
CLEANING, CV CARBURETOR......1244
INSPECTION, CV CARBURETOR......1244
ASSEMBLY, CV CARBURETOR......1245
FLOAT ADJUSTMENT, CV CARBURETOR......1246
NEEDLE & SEAT LEAKAGE TEST......1247
FUEL LEVEL......1247
FUEL PUMP SERVICE......1247
TROUBLESHOOTING......1249
CHAPTER 5-BODY AND STEERING......1251
TORQUE SPECIFICATIONS AND SPECIAL TOOLS......1252
PLASTIC INSERT REMOVAL/INSTALL......1252
SIDE PANEL REMOVAL......1253
FRONT COVER REMOVAL......1254
FOOT WELL REMOVAL/INSTALL......1254
FRONT STORAGE REMOVAL/INSTALL......1255
REAR RACK REMOVE/INSTALL......1257
FRONT CAB / FENDER REMOVE/INSTALL......1258
REAR CAB / FENDER REMOVE/INSTALL......1259
RADIATOR SCREEN REMOVAL......1260
BODY ASSEMBLY, EXPLODED VIEW......1261
HEADLIGHT POD, EXPLODED VIEW......1263
HANDLEBAR BLOCK INSTALLATION......1264
STEERING ASSEMBLY, EXPLODED VIEW......1265
A-ARM REPLACEMENT......1266
REAR SUSPENSION ASSEMBLY......1267
STRUT ASSEMBLY EXPLODED VIEW......1268
FRONT STRUT CARTRIDGE REPLACEMENT......1269
FRONT STRUT BALL JOINT REPLACEMENT......1269
STEERING POST ASSEMBLY......1270
DECAL REPLACEMENT......1270
CHAPTER 6-CLUTCHING......1271
SPECIAL TOOLS, SUPPLIES & TORQUES......1272
PVT SYSTEM OPERATION......1272
PVT MAINTENANCE/INSPECTION......1273
PVT DISASSEMBLY......1275
PVT ASSEMBLY......1276
PVT SEALING AND DUCTING COMPONENTS......1277
DRIVE CLUTCH EXPLODED VIEW......1277
DRIVE CLUTCH SPRING SPECIFICATIONS......1278
SHIFT WEIGHTS......1279
DRIVE CLUTCH INSPECTION......1280
DRIVE CLUTCH DISASSEMBLY......1280
DRIVE CLUTCH ASSEMBLY......1282
DRIVE BELT TENSION......1283
DRIVE BELT REMOVAL/INSPECTION......1284
DRIVE BELT INSTALLATION......1285
CLUTCH ALIGNMENT/OFFSET......1286
DRIVE CLUTCH BUSHING SERVICE......1287
DRIVEN CLUTCH DISASSEMBLY/INSPECTION......1289
DRIVEN CLUTCH ASSEMBLY......1291
DRIVEN CLUTCH BUSHING SERVICE......1291
EBS EXPLODED VIEW......1294
EBS DRIVE CLUTCH DISASSEMBLY/INSPECTION......1294
EBS DRIVE CLUTCH BUSHING SERVICE......1295
EBS DRIVEN CLUTCH DISASS./INSP......1297
EBS DRIVEN CLUTCH BUSHING SERV......1302
TROUBLESHOOTING......1304
CHAPTER 7-FINAL DRIVE......1307
FINAL DRIVE TORQUE SPECIFICATIONS......1308
AWD FRONT AXLE REMOVE/INSTALL......1308
AWD FRONT CV JOINT BOOT REPLACE......1310
AWD FRONT DRIVE AXLE EXPLODED VIEW......1314
FRONT HUB DISASS./ASSEMBLE......1311
AWD FRONT PROP SHAFT REMOVAL......1312
U-JOINT DISASSEMBLE/ASSEMBLE......1312
DRIVE AXLE / PROPSHAFT EXPLODED VIEW......1314
AWD FRONT GEARCASE OPERATION......1315
AWD FRONT GEARCASE SERVICE......1315
REAR HUB REMOVE/INSTALL......1325
REAR HUB DISASSEMBLY/ASSEMBLY......1327
REAR DRIVE SHAFT REMOVAL......1328
DRIVESHAFT / CV JOINT TIPS......1329
REAR DRIVESHAFT INSTALLATION......1329
REAR DRIVESHAFT SERVICE......1330
CHAPTER 8-TRANSMISSION......1333
TRANSMISSION MOUNTING......1334
TORQUE SPECIFICATIONS......1335
SPECIAL TOOLS......1335
TRANSMISSION REMOVAL......1335
TRANSMISSION INSTALLATION......1337
TRANSMISSION DISASSEMBLY......1339
TRANSMISSION ASSEMBLY......1346
TROUBLESHOOTING......1352
TRANSMISSION EXPLODED VIEW......1353
CHAPTER 9-BRAKES......1355
SPECIAL TOOLS/SPECIFICATIONS/TORQUES......1356
BRAKE SYSTEM COMPONENTS......1357
REAR CALIPER EXPLODED VIEW......1358
FRONT CALIPER EXPLODED VIEW......1358
REAR AUXILIARY MASTER CYLINDER EXPLODED VIEW......1359
BRAKE SYSTEM SERVICE NOTES......1359
BRAKE NOISE TROUBLESHOOTING......1359
HYDRAULIC BRAKE SYSTEM OVERVIEW......1360
HYDRAULIC CALIPER BLEEDING......1361
BRAKE BLEEDING / FLUID CHANGE......1361
MASTER CYLINDER REMOVAL......1363
MASTER CYLINDER INSTALLATION......1363
FRONT PAD REMOVAL......1364
FRONT PAD ASSEMBLY......1366
BRAKE BURNISHING......1367
FRONT DISC INSPECTION......1367
FRONT DISC REMOVAL/REPLACEMENT......1367
FRONT CALIPER REMOVAL......1368
FRONT CALIPER DISASSEMBLY......1368
FRONT CALIPER INSPECTION......1369
FRONT CALIPER REASSEMBLY......1369
FRONT CALIPER INSTALLATION......1370
REAR PAD REMOVAL......1371
REAR PAD INSTALLATION......1372
REAR CALIPER REMOVAL/INSPECTION......1373
REAR CALIPER REASSEMBLY......1374
REAR DISC INSPECTION......1375
REAR (AUXILIARY) BRAKE REMOVE/INSTALL......1376
TROUBLESHOOTING......1377
CHAPTER 10-ELECTRICAL......1379
SPECIAL TOOLS/SERVICE NOTES......1380
GEAR POSITION SWITCH TEST......1380
ECM OPERATION......1381
ELECTRICAL COMPONENTS......1382
INSTRUMENT CLUSTER OPERATION......1383
SPEEDOMETER REMOVAL/INSTALLATION......1387
SPEEDOMETER TROUBLESHOOTING......1388
COOLANT SENSOR TESTS......1393
FAN MOTOR TESTS......1393
ELECTRONIC THROTTLE CIRCUIT SYSTEM OPERATION......1394
IGNITION SYSTEM INFORMATION......1395
IGNITION SYSTEM TESTING FLOW CHART......1397
IGNITION SYSTEM TROUBLESHOOTING......1398
CDI OUTPUT TESTS......1398
CHARGING SYSTEM TESTING......1398
TIMING CHECK PROCEDURE......1400
BATTERY ACTIVATION/SERVICE......1402
HEAD LIGHT/BRAKE LIGHT LAMP SERVICE......1409
FUEL SENDER TEST......1413
ACCESSORY WIRE HOOKUP......1414
WARN™ WINCH WIRING SCHEMATIC......1415
STARTER SYSTEM TROUBLESHOOTING......1416
STARTER MOTOR SERVICE......1417
STARTER DRIVE......1419
STARTER ASSEMBLY EXPLODED VIEW......1419
STARTER SYSTEM TESTING FLOW CHART......1420
WIRING DIAGRAMS......1420
INDEX......1423
A-C......1423
C-E......1424
E-G......1425