2005 POLARIS SPORTSMAN 400 MANUAL PDF

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Polaris Sportsman 400 Service Manual

Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure 4400 water tight fit between the seal and the cover on engine side. Rear Wheel Nuts 20 Ft.

Using a multitester set on D. Use electrical contact cleaner to clean starter motor parts. By pressing ‘print’ button you will print only current page. Install outer yoke, aligning marks made before disassembly.

Owner’s Manuals

Do not allow the lip of the seals to turn in- side out or fold. Clean caliper area before removal.

Inspect moveable sheave bushing for wear. Spring Position sheave – projex inbox. From outside of clutch ploaris, insert removal tool Item 3 into cover bushing. Measure clearance between outer feed rotor and pump body with a feeler gauge. Measure rotor tip clearance with a feeler gauge.

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Always check piston ring installed gap before rings are installed on piston. Remove bolts and recoil housing. Transmission Installation – projex inbox.

Start bearing in housing. Inspect each rocker arm cam follower surface.

Check friction pads for wear, damage and looseness. Piston should slide in and out of bore smoothly, with light resistance. Thoroughly clean the ATV engine and chassis. Set handlebars in a straight ahead position and secure handlebars in polarix position. Recoil Housing – projex inbox. This should also be done before storing the ATV. Cooling System Specifications Using manuual water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage.

Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to ppolaris clearance, clutch balance and shifting pattern.

Stretch silent cluster chain tight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain.

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Replace the spring if tabs are misaligned or the spring coils are distorted. The automatic compression release mecha- nism can be inspected and serviced without removing the camshaft from the cylinder head. Photo at right is shown without shaft for Snap ring located in clarity. Support caliper so as not to kink or bend brake sporteman.

Crankcase Assembly – projex inbox. To replace, press new bearing on to shaft.

POLARIS SPORTSMAN SERVICE MANUAL Pdf Download.

The replacement spring is PN All voltages are with reference to pin B ground. Valve Sealing Test – projex inbox. Nothing flashy, just all the information you need for a co mplete repair and or rebuild of your Polaris that you can view on your Remove left side shock absorber.