Polaris Sportsman Manual Chapters:
Quick Reference Data
Chapter One/General Information
Manual organization/Warnings, cautions and note/Safety/Serial numbers/Model identification (2004 models)/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications
Chapter Two/Troubleshooting
Warning light system/Starting the engine/Engine will not start/Starting difficulties/Poor engine performance/Fuel system/Engine/Engine lubrication/Cylinder leakdown test/Clutch system/Electrical testing/Electrical troubleshooting/Meter assembly/Front gearcase/Steering/Steering/Brake system/Specifications
Chapter Three/Lubrication, Maintenance and Tune-Up
Maintenance schedule/Pre-ride inspection/Tune-up/Engine compression test/Engine oil and filter/Oil pressure test/Clutch/Transmission oil/Shift linkage/Air filter/Inline breather filter/Air intake ducts/Idle speed (carbureted models)/Control cables/Fuel system/Exhaust system/Ignition timing (2002-2004 carbureted models)/Spark plugs/Cooling system/Front gearcase oil/Rear gearcase oil (all models except X2 and Touring models)/Tires and wheels/Steering system/Suspension/Brake system/Lighting system/Recoil starter/Lubrication service/Fasteners/Wires, hoses and control cables/Specifications
Chapter Four/Engine Top End
Component identification/Rocker cover/Rocker arms and pushrods/Cylinder head/Cylinder block and pistons/Valve lifter/Specifications
Chapter Five/Engine Lower End
Engine service/Oil system priming/Engine removal/Engine installation/Recoil starter (MV7 models)/Alternator covers (all models except MV7)/Flywheel, bendix and stator/Water pump cover/Stator housing/Timing gears/Water-oil pump/Camshaft thrust plate/Crankcase/Engine break-in/Specifications
Chapter Six/Clutch and Drive Belt System
Clutch system operation/Clutch tools/Clutch drying/Drive belt/Clutch outer cover/Clutch inner cover/Drive clutch/Driven clutch/Specifications
Chapter Seven/Transmission and Shift Mechanism (All Models Except X2 and Touring Models)
Gearshift selector/Transmission case/Transmission/Specifications
Chapter Eight/Transmission and Shift Mechanism (X2 and Touring Models)
Gearshift selector/Transmission case/Transmission shafts/Differential gear assembly/Snorkel shaft/Specifications
Chapter Nine/Air-Fuel and Exhaust System (Carbureted Models)
Air box/Exhaust system/Intake manifold/Carburetor/Carburetor tests and adjustments/Pilot screw/Throttle cable/Throttle lever housing/Choke (starter) cable/Fuel draining/Fuel valve/Fuel tank/Rear tank (2005-on MV7 models)/Fuel sender (later 2004-on 600 and 700 models, 2005-on MV7 models)/Fuel pump/Specifications
Chapter Ten/Air-Fuel System (Fuel-Injected Models)
Air box/Exhaust system/Exhaust manifold/Priming the Fuel System/Depressurizing the fuel system/Fuel tank/Fuel pump/Fuel sender/Pressure regulator/Throttle lever housing/Throttle cable/Throttle body/Fuel injectors/Crankshaft position (CKP) sensor/Temperature and barometric air pressure (T-BAP) sensor/Throttle position sensor (TPS)/Electronic control unit (ECU)/Self diagnosis/Specifications
Chapter Eleven/Electrical System
Electrical component replacement/Electrical connectors/Battery/Charging system/Stator/Voltage regulator-rectifier/Logic box (2005-on carbureted models)/Relays/Ignition system identification/CDI unit/Trigger coil/Ignition coil/Electronic control unit (ECU)/Starting system/Starter/Starter solenoid/Electronic throttle control (ETC) switch/Headlight pod/Headlight/Taillight assembly/Work light (models so equipped)/Switches/All wheel drive (AWD) coil/Active descent control (ADC) coil/Speed sensor/Transmission switch/Resistor module (2004-on models)/Shift indicator circuit/Differential solenoid (X2 and Touring models)/Differential controller relay (X2 and Touring models)/Meter assembly/On-board diagnosis/Fuses/Wiring and connectors/Wiring diagrams/Specifications
Chapter Twelve/Cooling System
Hoses and hose clamps/Cooling system inspection/Coolant reservoir/Radiator/Radiator fan/Fan switch (2002-2004 600 and 700 models)/Coolant temperature sensor/Thermostat/Water pump/Specifications
Chapter Thirteen/Wheels, Tires and Hubs
Wheels/Front hub/Front bearing carrier/Rear hub/Rear bearing carrier/Tires/Specifications
Chapter Fourteen/Front Suspension, Steering and Front Drive System
Hubstrut/Front strut/A-arm/Tie rod/Steering post/Handlebar/Handlebar grip/Front drive axle/Front drive shaft/Universal joint/Front gearcase/Specifications
Chapter Fifteen/Rear Suspension and Rear Drive System
Shock absorber/Upper control arm/Lower control arm/Control arm inspection/Stabilizer linkage assembly/Stabilizer support/Rear drive axle/Rear gearcase (all models except X2 and Touring models)/Rear drive shaft (all models except X2 and Touring models)/Specifications
Chapter Sixteen/Brakes
Brake operation/Brake service notes/Brake bleeding/Brake fluid draining/Brake pad inspection/Front brake caliper/Rear brake caliper/Front brake master cylinder/Rear brake master cylinder/Brake pedal/Brake disc/Brake hoses/Specifications
Chapter Seventeen/Body and Frame
Quick release inserts/Rider’s seat/Rider’s backrest and passenger seat (X2 models)/Passenger seat (Touring models)/Side panel/Fender cover/Front fender/Front rack/Front bumper (all models except MV7)/Front brush guard/Grill and radiator shield (all models except MV7 models)/Rear rack (all models except MV7, X2 and Touring models)/Rear rack (Touring models)/Rear rack and brush guard assembly (MV7 models)/Rear quarter panel (X2 models)/Footwell/Rear storage box (all models except M2 models)/Cargo box (X2 models)/Winch/Winch contactor/Specifications
Index
