Every Clymer contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of the
ATV. This, in addition to extensive research, allows Clymer to achieve an un-matched level of detail, accuracy & clarity.
The step-by-step instructions and two column text with large print are user friendly, bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb tabbed chapters, numbered table of contents and extensive index make it possible to locate the desired section quickly.
Models Covered:
2001-2005 POLARIS Sportsman 400
|
2011-2013 POLARIS Sportsman 400
HO |
2006-2007 POLARIS Sportsman 450
|
2006 POLARIS Sportsman 450
Browning Edition |
1996-2010 POLARIS Sportsman 500 |
2001-2002 POLARIS Sportsman 500
DUSE |
2001-2006, 2008-2013 POLARIS
Sportsman 500 HO |
2000-2002 POLARIS Sportsman 500
RSE |
2008-2013 POLARIS Sportsman 500
Touring |
2006-2010 POLARIS Sportsman 500
X2 |
1997-2001 POLARIS Worker 500
|
1997 POLARIS Xplorer 500 |
******
This manual does not cover 500 ATP HO models.
*******
Contents:
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
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
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
INDEX
COLOR WIRING DIAGRAMS
Models covered
Sportsman 400 2001 2002 2003 2004 2005
Sportsman 450 2006-2007
Sportsman 450 Browning Edition 2006
Sportsman 500 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
2009 2010
Sportsman 500 RSE 2000 2001 2002
Sportsman 500 DUSE 2001 2002
Sportsman 500 HO 2001 2002 2003 2004 2005 2006, 2008 2009 2010
Sportsman 500 X2 2006 2007 2008 2009 2010
Sportsman Touring 500 2008 2009 2010
Worker 500 1997 1998 1999 2000 2001
Xplorer 500 1997 For Shipping Rates Please Click Here (A new window will open — simply close window to continue shopping.)