Polaris, Sportsman 400, 450, 500, Worker 500, Xplorer 500, EFI, 1996, 1997, 1998, 1999,2000,2001, 2002,2003, 2004, 2005,2006,2007, 2008, 2009, 2010,2011,2012,2013, pdf, repair
How to fix your used ATV, quad with the help of this professional electronic PDF download version of the detailed and specific Polaris Sportsman 400, 450, 500 workshop manual / repair guide.
Production/model years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 09, 09, 10, 11, 12, 13
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 Language: English
Manual format: PDF / e-book (zip)
Delivery: Download link will appear on the checkout page after your payment is complete.
Availability: Instant download
This complete digital download version is the same OEM manual used by official certified professional Polaris Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI mechanics and by local dealership / technicians or engineers for service, maintenance and repairs.
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leak down test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly /
Engine oil level check / Engine oil and filter change / Oil pump priming / Oil pressure test / Transmission oil level check / Transmission oil change / Front gear case oil level change / Front gear case 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 /
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 / 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 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
Air cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gear case oil seal inspection and replacement / Shift selector linkage / Specifications
Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications
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 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 wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / Specifications
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
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