Polaris Sportsman 400, 450 & 500, 1996 - 2013

Clymer Owners Service & Repair Manual

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013

by Clymer Staff

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Polaris Sportsman 400, 450 & 500, 1996 - 2013 - Front Cover

Front Cover

Front Cover

description

Polaris Sportsman 400, 450 & 500, 1996 - 2013 Clymer Owners Service & Repair Manual covers the following models:
● Sportsman 400 (2001 - 2005)
● Sportsman 400 HO (2011 - 2013)
● Sportsman 450 (2006 - 2007)
● Sportsman 450 Browning Edition (2006)
● Sportsman 500 (1996 - 2010)
● Sportsman 500 RSE (2000 - 2002)
● Sportsman 500 DUSE (2001 - 2002)
● Sportsman 500 HO (2001 - 2006, 2008 - 2013)
● Sportsman 500 X2 (2006 - 2010)
● Sportsman Touring 500 (2008 - 2013)
● Worker 500 (1997 - 2001)
● Xplorer 500 (1997)

Manual covers all models with EFI
Does Not cover 500 ATP HO models

Contents:
Quick Reference Data
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
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
Lubrication, Maintenance And Tune-Up
Engine Oil Level Check / Engine Oil And Filter Change / Oil Pump Priming / Oil Pressure Test / Transmission Oil Level Check / Transmission Oil Change / Front Gearcase Oil Level Change / Front Gearcase Oil Change / Front Hub (1996-early 2004 Models) Oil Level Check / Front Hub (1996-early 2004 Models) Oil Change / Clutch Draining And Drying / Clutch Belt Inspection / Air Filter Service / Fuel Tank Vent Hose / Fuel Hose Inspection / Fuel Filter Service / Brake System / Control Cable Lubrication Throttle Cable/Electronic Throttle Control (ETC) Adjustment / Throttle Cable Adjustment / Choke Cable Inspection / Cooling System Inspection / Coolant Level Check / Exhaust System / Suspension / Tires And Wheels / Toe-In Adjustment Alignment / Lubrication Service: Front Suspension Arms , Front Struts, Lower End Of The Steering Shaft, Front Drive Axle Inner U-Joints, Front Propeller Shaft, Front U-Joints, Rear U-Joint, Upper And Lower Rear Suspension Arms, And Rear Bar Stabilizer Assembly / Fastener Inspection / Valve Clearance / Compression Test / Spark Plug / Ignition Timing / Idle Speed / Specifications
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
Engine Lower End
Flywheel And Stator Plate / Recoil Starter / Crankcase / Oil Pump / Oil System One-Way Check Valve / Break-In Procedure / Specifications
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
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
Cooling System
Air Cooling System / Liquid Cooling System / Hoses And Hose Clamps / Radiator / Cooling Fan / Coolant Pump / Thermostat / Specifications
Clutch And Drive Belt
Clutch System Operation / Clutch Tools / Clutch Drying / Drive Belt / Belt Alignment / Drive Clutch / Driven Clutch / Specifications
Transmission (1996-early 2004 Models)
Transmission / Transmission Inspection / Shift Shafts / Front Output Shaft / Transmission Gearcase Oil Seal Inspection And Replacement / Shift Selector Linkage / Specifications
Transmission (Late 2004-On Models)
Transmission / Transmission Shafts / Differential Gear Assembly / (X2 And Touring Models) / Snorkel Shaft / Shift Selector Linkage / Specifications
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
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
Front Suspension And Steering
Front Wheel / Front Strut / Front Strut Cartridge And Spring / Control Arm / Handlebar / Tie Rods / Steering Post / Tires And Wheels / Specifications
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
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
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

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599696398 (1-599-69639-8)
  • ISBN-13: 9781599696393 (978-1-599-69639-3)
  • Format: Softcover, 730 pages
  • Date Published: 2013

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