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1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 1
1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 2
1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 3
1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 4
1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 5
1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual Preview image 6

1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual

Models covered in this manual:

  • Polaris Inc 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)

Production/model years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013.

File specifications

File size: 71.68 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 1.47 Minutes
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Product Information

Table of Contents

CHAPTER ONE / GENERAL INFORMATION

  1. Manual organization
  2. Warnings, cautions and notes
  3. Safety
  4. Serial numbers
  5. Model identification (2008 models)
  6. Fasteners
  7. Shop supplies
  8. Tools
  9. Measuring tools
  10. Electrical system fundamentals
  11. Service methods
  12. Storage
  13. Specifications

CHAPTER TWO / TROUBLESHOOTING

  1. Water damage
  2. Starting the engine
  3. Engine does not start
  4. Poor engine performance
  5. Electronic throttle control (ETC)
  6. Fuel system
  7. Engine
  8. Engine lubrication
  9. Cylinder leakage test
  10. Electrical system
  11. Steering
  12. Suspension / Drive system
  13. Front suspension and steering
  14. Brake system
  15. Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

  1. Engine oil / Gearcase oil / Engine oil and filter change
  2. Oil pump priming
  3. Oil pressure test
  4. Transmission oil level check / Transmission oil change (X2 models)
  5. Cooling system coolant change
  6. Radiator inspection and repair / Radiator removal / Cooling fan / Coolant pump / Thermostat
  7. Carburetor pilot screw adjustment
  8. Battery maintenance
  9. Electrical connections
  10. Lights and switches
  11. Spark plugs / Ignition timing
  12. Valve adjustment (2009 models)
  13. Valve clearance adjustment
  14. Compression check
  15. Cylinder leakage test
  16. Fuel filter replacement
  17. Fuel tank removal and installation
  18. Air filter replacement
  19. Brake inspection and maintenance
  20. Drive system
  21. Suspension / General lubrication
  22. Tire replacement / Wheel alignment / Front wheel toe adjustment
  23. Specifications

CHAPTER FOUR / ENGINE

  1. Engine components
  2. Engine removal and installation
  3. Cylinder head / Camshaft / Valve lifters / Cylinder head disassembly / Cylinder head assembly / Piston / Cylinder / Connecting rod / Crankshaft / Crankshaft disassembly / Crankshaft assembly / Engine break-in / Specifications

CHAPTER FIVE / FUEL SYSTEM AND AIR INTAKE

  1. Fuel tank / Carburetor / Fuel pump
  2. Carburetor removal / Cleaning / Inspection / Installation
  3. Throttle cable adjustment / Air filter cleaning / Specifications

CHAPTER SIX / ELECTRICAL SYSTEM

  1. Electrical system operation
  2. Electrical system maintenance
  3. Battery / Charging system / Stator / Voltage regulator / Ignition system / Ignition timing / CDI module / Ignition coil / Spark plug / Starter motor / Drive / Switches / Lighting system / Specifications

CHAPTER SEVEN / DRIVE TRAIN

  1. Front drive housing (1996-1998 models) / Front drive shaft / Universal joint / Transmission removal / Transmission disassembly / Transmission assembly / Transmission installation / Shift selector linkage / Shift cable adjustment / Transmission specifications

CHAPTER EIGHT / COOLING SYSTEM

  1. Air-cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications

CHAPTER NINE / CLUTCH AND DRIVE BELT

  1. Clutch system operation / Clutch tools / Clutch spring / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications

CHAPTER TEN / TRANSMISSION (1996-early 2008 models)

  1. Transmission / Transmission specifications / Shift shaft / Front output shaft / Transmission service / Shift linkage and adjustment / Belt removal and installation / Specifications

CHAPTER ELEVEN / TRANSMISSION (late 2008-2013 models)

  1. Transmission / Transmission shafts / Transmission assembly / Shift selector / Shift cable adjustment / Shift linkage / Transmission removal and installation / Transmission service / Specifications

CHAPTER TWELVE / FRONT DRIVE SYSTEM

  1. Front drive and modular clutch (1996-1998 models) / Front hub / Front output shaft / Universal joints / Front drive and axle boots and grease / Steering knuckles and bearings / Front axle / Front differential (2008 models) / Front gearcase (1996-1998 models) / Gearcase service / Front drive shaft (1999-2013 models) / Specifications

CHAPTER THIRTEEN / REAR DRIVE SYSTEM

  1. Rear drive and modular clutch (1996-1998 models) / Rear hub / Rear axle / Rear wheel bearings / Rear drive and axle boots and grease / Rear drive shaft / Rear gearcase (1999-2013 models) / Gearcase service / Rear differential / Rear drive housing service / Rear gearcase service / Specifications

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING

  1. 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

  1. Shock absorber / Rear frame and suspension carrier / Rear drive axle / Rear axle and boots / Independent rear suspension (1999-2013 models) / Rear frame axle (X2 and Touring) / Lower control arm (all models except X2 and Touring) / Upper control arm (all models except X2 and Touring) / Stabilizer arm support (all models except X2 and Touring) / Stabilizer support bar / Lower control arm (X2 and Touring) / Stabilizer support bar (X2 and Touring) / Specifications

CHAPTER SIXTEEN / BRAKES

  1. Brake system / Brake pad replacement / Front caliper / Output shaft (1996-1998 models) / Output shaft (2009 models) / Brake caliper (1996-1998 models) / Brake pad replacement / Brake system inspection / Brake rotor replacement / Brake cable adjustment / Brake lever and pedal adjustment / Hydraulic brake system bleeding / Parking brake cable adjustment / Rear brake caliper replacement / Rear brake pedal / Brake disc / Specifications

CHAPTER SEVENTEEN / BODY AND FRAME

  1. Plastic covers / Side covers / Fender / Front cover / Front fender / Front bumper / Rear bumper / Body panel replacement / Seat removal and installation / Headlight cover / Fuel tank cover / Storage box (X2 models) / Rear rack / Rear cargo box / Tail lamp (X2 models) / Cargo box replacement / Cargo box removal / Cargo box installation / Specifications
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