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Do not release lever before bleeder screw is spodtsman or air may be drawn into caliper. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.

Polaris Sportsman Manual | eBay

Check drain plug for proper torque. Cooling System – projex inbox. Side Panel Removal – projex inbox. Install caliper on hub strut, and torque mounting bolts. Serious injury could occur if machine tips or falls.

Normally positioned so part numbers are easily read. Pvt Disassembly – projex inbox.

Polaris Sportsman 400 Service Manual

Remove three Phillips screws at back of headlight pod. Check all connections for leaks and repair if necessary. Inspection may reveal the need for re- placement parts. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring.


Using a common spring loaded finger type glaze breaker for honing is never advised. A gritty feeling indicates contamination.

If cylinder is tapered or out of round beyond. Shift Weight Inspection, Button To Tower Clearance Inspection All PVT system maintenance repairs must be per- formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual.

Spacer Tab Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.

Owner’s Manuals

Look for discoloration, shiny spots, or and area that looks different than the rest of the needle. Cylinder Head Exploded View – projex inbox. Install flywheel puller PN and remove flywheel. Sealing Washers 15 ft.

Remove all cover bolts. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge. Page 30 – projex inbox. Belt burnt, thin -Abuse continued throttle application when -Caution operator to operate machine within guidelines. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side.


Position the piston support block PN A beneath the piston skirt to support the piston during cylinder installation. Decimal Equivalents – projex inbox.

Body Assembly, Exploded View Stretch chain tight on a flat surface and apply a 10 lb. Remove the zportsman 6mm flange bolts A from cylinder head. Lubricate automatic compression release mechanism with clean engine oil. Loosen three camshaft sprocket bolts.

Owner’s Manuals | Polaris

In order to remove the bushing it will be necessary to apply heat. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts. CDI boxes may look the same but have different internal circuitry. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re- pair and adjustment be performed by an authorized Polaris Dealer.

Page 6 – projex inbox.