Polaris Sportsman Service and Repair Manual
400, 450 and 500 ATV Models
This product has been updated.
Please see the updated Polaris Sportsman Manual
The Polaris Sportsman repair and service manual covers these Polaris Sportsman ATV's for these years:
- 2001 Polaris Sportsman 400
- 2002 Polaris Sportsman 400
- 2003 Polaris Sportsman 400
- 2004 Polaris Sportsman 400
- 2005 Polaris Sportsman 400
- 2006 Polaris Sportsman 450 (including Browning Edition)
- 2007 Polaris Sportsman 450
- 1996 Polaris Sportsman 500
- 1997 Polaris Sportsman 500 (including Polaris Xplorer and Worker)
- 1998 Polaris Sportsman 500 (including Polaris Worker)
- 1999 Polaris Sportsman 500 (including Polaris Worker)
- 2000 Polaris Sportsman 500 (including RSE and Worker)
- 2001 Polaris Sportsman 500 (including HO, RSE, DUSE, and Worker)
- 2002 Polaris Sportsman 500 (including DUSE and RSE)
- 2003 Polaris Sportsman 500 (including HO)
- 2004 Polaris Sportsman 500 (including HO)
- 2005 Polaris Sportsman 500 (including HO)
- 2006 Polaris Sportsman 500 (including HO and X2)
- 2007 Polaris Sportsman 500 (including X2)
- 2008 Polaris Sportsman 500 (including Touring, HO and X2)
Note: this manual does not cover Polaris 500 ATP HO models.
Buy the Polaris Sportsman manual for the 400, 450 and 500 series and learn to perform every service and repair procedure on your Sportsman ATV. Clymer repair manuals are written for the do-it-yourself mechanic and the experienced pros. This service manual contains many original photographs, illustrations and wiring diagrams obtained from the complete teardown and rebuild of the Polaris Sportsman. This, in addition to extensive research is how Clymer repair manuals achieve an unmatched level of detail and accuracy.
Polaris Sportsman Manual Contents:
- General Information
- Troubleshooting
- Lubrication, Maintenance and Tune-up
- Engine Top End
- Engine Lower End
- Carburetor and Fuel System
- Fuel Injection System
- Cooling System
- Clutch and Drive Belt
- Transmission
- Front Drive System
- Electrical System
- Suspension and Steering
- Brakes
- Body
- Index
- Color Wiring Diagram
The Polaris Sportsman Service Manual Applies to the Following Years:
- 1996, 1997, 1998, 1999
- 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
Polaris Sportsman Model Name Variations:
Sportsman 400, Sportsman 450, Sportsman 500, Sportsman Browning Edition, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 HO, Sportsman 500 X2, Sportsman 500 Touring, Worker 500, Xplorer 500
Tags: Polaris, Sportsman, Service, Repair, Manual, Clymer, 400, 450, 500
- Publisher: Clymer Manuals - 2008
- Author: Clymer Staff
- Binding: Paperback - 8.25 x 11 x 1.5 inches
- Pages: 688 - Hundreds of b&w photos and illustrations
- ISBN: 9781599692425
Use the "Buy Now" button at the top of this page to purchase the Polaris Sportsman Manual.
Polaris Sportsman Repair Manual Chapters:
QUICK REFERENCE DATA
CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Model identification (2004 models) | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications
CHAPTER TWO: TROUBLESHOOTING
Water damage | Starting the engine | Engine does not start | Poor engine performance | Electronic throttle control (ETC) | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch system | Gearshift linkage | Transmission | Electrical testing | Electrical troubleshooting | Meter assembly | Front gearcase | Final drive | Front suspension and steering | Brake system | Specifications
CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Engine oil | Oil pump priming | Oil pressure test | Transmission | Front gearcase oil | Front hub (1996-early 2004 models) | Clutch | Air filter | Fuel tank vent hose | Fuel hose and filter | Brake system | Control cables | Cooling system | Exhaust system | Suspension | Tires and wheels | Lubrication service | Fastener inspection | Valve clearance | Compression test | Spark plug | Ignition timing | Idle speed | Specifications
CHAPTER FOUR: ENGINE TOP END
Engine service | Engine cooling | Engine lubrication | Servicing the engine in the frame | Exhaust system | Cylinder head cover | Rocker arm assembly | Camshaft | Cylinder head | Valves and valve components | Cylinder block | Piston and piston rings | Camshaft chain and sprockets | Break-in procedure | Specifications
CHAPTER FIVE: ENGINE LOWER END
Engine | Flywheel and stator plate | Recoil starter | Crankcase | Oil pump | Oil system one-way check valve | Break-in procedure | Specifications
CHAPTER SIX: CARBURETOR and FUEL SYSTEM
Carburetor operation | Carburetor | Carburetor tests and adjustments | Throttle cable replacement | Starting enrichment (choke) cable | Fuel tank | Fuel shutoff valve | Fuel level sending unit (2004-on models) | Air filter air box | Fuel pump | Specifications
CHAPTER SEVEN: FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure | Depressurizing the fuel system | Fuel line fittings | Throttle body | Fuel rail and fuel injector | Fuel pump | Fuel sender | Pressure regulator | Fuel tank | Crankshaft position sensor (CPS) | Manifold air pressure (MAP) sensor | Intake air temperature (IAT) sensor | Idle air control (IAC) | Throttle position sensor (TPS) | Engine coolant temperature (ECT) sensor | Electronic control module (ECM) | Self diagnosis | Throttle cable replacement | Air filter air box | Specifications
CHAPTER EIGHT: COOLING SYSTEM
Air cooling system | Liquid cooling system | Hoses and hose clamps | Radiator | Cooling fan | Coolant pump | Thermostat | Specifications
CHAPTER NINE: CLUTCH and DRIVE BELT
Clutch system operation | Clutch tools | Clutch drying | Drive belt | Belt alignment | Drive clutch | Driven clutch | Specifications
CHAPTER TEN: TRANSMISSION (1996-EARLY 2004 MODELS)
Transmission | Transmission inspection | Shift shafts | Front output shaft | Transmission gearcase oil seal inspection and replacement | Shift selector linkage | Specifications
CHAPTER ELEVEN: TRANSMISSION (LATE 2004-ON MODELS)
Transmission | Transmission shafts | Differential gear assembly (X2 and Touring models) | Snorkel shaft | Shift selector linkage | Specifications
CHAPTER TWELVE: FRONT DRIVE SYSTEM
Front hub and Hilliard clutch (1996-early 2004 models) | Front hub (late 2004-on, X2 and Touring models) | Front drive axle, boots and constant velocity (CV) joints | Front drive shaft | Front gearcase | Front gearcase-Deluxe models with active decent control (2007-on Sportsman 500, X2 and Touring models) | Specifications
CHAPTER THIRTEEN: ELECTRICAL SYSTEM
Electrical basics | Electrical component replacement | Electrical connectors | Battery | Battery negative terminal | Charging system | Alternator stator | Voltage regulator | rectifier (1996-early 2004 carbureted models) | Logic box (late 2004-2006 carbureted models) | Capacitor discharge ignition (carbureted models) DC | Ignition system (fuel injected models) | Ignition coil | Electric starting system | Starter drive gears | Starter solenoid | Headlight system | Taillight and work light | Indicator lamp (1996-2002 models) | Speed sensor | Transmission switch | Resistor module (2004-on models) | Shift indicator circuit (late 2004-on models) | Differential solenoid (X2 and Touring models) | Switches | Electronic throttle control (ETC) switch | All wheel drive (AWD) coil | Active descent control (ADC) coil (2007-on X2 and Touring models) | Cooling system switch and sensor | Fuses and circuit breaker (2008 models) | Speedometer | On-board diagnostics | Winch (models so equipped) | Winch contactor (models so equipped) | Specifications
CHAPTER FOURTEEN: FRONT SUSPENSION and STEERING
Front wheel | Front strut | Front strut cartridge and spring | Control arm | Handlebar | Tie rods | Steering post | Tires and wheels | Specifications
CHAPTER FIFTEEN: REAR SUSPENSION and FINAL DRIVE
Rear wheel | Shock absorber | Rear hub and bearing carrier | Rear drive axle | Rear drive axle boot replacement (1996-1998 models) | Rear drive axle CV joint and boots (1999-on models) | Upper control arm (all models except X2 and Touring) | Lower control arm (all models except X2 and Touring) | Upper control arm (X2 and Touring models) | Lower control arm (X2 and Touring models) | Upper and lower control arm inspection | Stabilizer linkage (all models except X2 and Touring) | Stabilizer support (all models except X2 and Touring) | Stabilizer support and bar (X2 and Touring models) | Specifications
CHAPTER SIXTEEN: BRAKES
Brake service | Front brake pad replacement | Front caliper | Output shaft brake pad replacement (1996-1997 models) | Output shaft brake caliper (1996-1997 models) | Output shaft brake pad replacement (1998-2002 models) | Output shaft brake caliper (1998-2002 models) | Rear brake pad replacement (2003-on models except X2 and Touring) | Rear caliper (2003-on models except X2 and Touring) | Rear brake pad replacement (X2 and Touring models) | Rear caliper (X2 and Touring models) | Front master cylinder | Rear master cylinder | Brake hose replacement | Brake bleeding tips | Brake bleeding | Brake fluid draining | Rear brake pedal | Brake disc | Specifications
CHAPTER SEVENTEEN: BODY and FRAME
Plastic inserts | Seat | Side panel | Fender cover | Front fender | Front rack, rail and grille (1996-2004 models) | Front rack and storage box (2005-on models) | Front bumper | Radiator guard (1996-2003 models) | Radiator brush guard (2004-on models) | Brush guard grill and radiator side shield (2004-on models) | Rear rack, rail and bumper (1996-2002 models) | Rear rack and rail (2003-on except X2 and Touring) | Rear rack and handle (Touring models) | Rear fender | Rear quarter panel (X2 models) | Footwell | Footwell support bracket (X2 and Touring models) | Rear storage box (all models except X2 and Touring) | Cargo box (X2 models) | Specifications
COLOR WIRING DIAGRAMS
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