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Polaris sportsman 400 manual
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Select your ride to ensure proper product fitment. Answers provided by other customers are solely the views and opinions of those customers. A staple in the industry for more than 42 years. Return any new, unused item within 30 days. Accessibility Toggles for ChapMoto. Powersports and Motorcycle Gear, Parts and Accessories. Top element. Offroad Vehicle Polaris Sportsman 400 H. SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL. GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Model Option Year Designation Basic Chassis Designation Engine Designation. GENERAL INFORMATION REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. GENERAL INFORMATION MODEL COLOR IDENTIFICATION SPORTSMAN 500 H. GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 400 22 in 55. GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 400 81 in 205. GENERAL INFORMATION MACHINE DIMENSIONS 45 in SPORTSMAN 400 114. CHASSIS DRIVE TRAIN Body Style . GENERAL INFORMATION SPORTSMAN 500 H. GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. AC 9915754 9916443 9916444 2001 Sportsman 500 DUSE A01CH50AD 9915754 9916002 9916003 2001 Sportsman 500 H. GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch 1. GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. Distance between center of crankshaft and center of driven clutch shaft. Polaris measures chain length in number of pitches. Total distance between piston and cylinder wall. Regulates battery charging system output at approx. CHAPTER 2 MAINTENANCE Periodic Maintenance Chart . Recommended Lubricants and Capacities . Inspect, clean, lubricate, adjust or replace parts as necessary. Always use genuine Polaris parts. Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. MAINTENANCE PERIODIC MAINTENANCE CHART, CONT. Lubricate All Fittings, Pivots, Cables, Etc. Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. Brake Fluid dicated level inside reservoir. Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special. S Be sure vehicle is level before proceeding. S Check vent hose to be sure it is routed properly and unobstructed. Gear Lube, or an equivalent lubricant with a GL5 rating. Linkage rod will rotate sion linkage can be adjusted. S Tighten shift linkage rod end jam nuts properly after adjustment. MAINTENANCE SHIFT LINKAGE ADJUSTMENT, CONT. Make sure the transmission bell cranks are engaged in the neutral position detents. Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Throttle lever operation should be smooth and lever must return freely without binding. Place the gear selector in neutral. Slide boot off throttle cable adjuster and jam nut. Place shift selector in neutral and set parking brake. Start engine and set idle to specified RPM, then shut off engine. MAINTENANCE FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. The bowl drain screw is located on the bottom left side of the float bowl. Stroke engines are equipped with an automatic decompressor. Smooth idle generally indicates good compression. MAINTENANCE BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. Serious burns can result from contact with skin, eyes or clothing. Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Remove spark plug high tension lead. Inspect electrodes for wear and carbon buildup. S Overheating of engine could occur if air is not fully purged from system. TYPE Test the strength of the coolant using an antifreeze hydrometer. Inner splash cap vent hole must be clear and open. FILTER SERVICE It is recommended that the air filter and pre filter be replaced Cover annually. Gasket The pre filter should be cleaned before each ride, using the following procedure. MAINTENANCE AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube. MAINTENANCE RECOIL HOUSING S Drain the housing periodically to remove moisture. S Drain filexlib.
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