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Mark drive belt direction of rotation so that it can be installed in the same direction. Measure piston pin O.

Owner’s Manuals | Polaris

Repeat steps to install bearing caps on outer yoke. Disassemble the roller clutch and thoroughly clean all parts. When riding in extremely dusty conditions re- placement will be required more often. Remove lower A-arm from ball joint. Install and torque both lower control arm bolts.

Polaris Sportsman 400 Service Manual

Install all spoftsman bolts finger tight. Force U-joint cross to one side and lift out of inner yoke. S Overheating of engine could occur if air is not fully purged from system.

Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary.


Page 91 – projex inbox. Do not store or use a partial bottle of brake fluid. Release the ratchet pawl A and push the tensioner plunger B mxnual the way into the tensioner body. Camshaft Inspection – projex inbox. Front Gearcase Lubrication S Be sure vehicle is level before proceeding. Tabs face shaft 5. Awd Armature Plate Inspection – projex inbox. Using a digital multitester, measure the resistance between the cable terminal and janual insulated brush.

Piston Installation – projex inbox. Crankcase Assembly – projex inbox. 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.

Page 28 – projex inbox. Install main adapter Item 8 on puller. Rear Drive Shaft Removal – projex inbox. To change fluid, 200 selector box assembly, disassemble, clean, and assemble.

Polaris Sportsman Manual | eBay

To install housing, reverse removal procedure. Remove all carbon from valve with a soft wire wheel. Page 84 – projex inbox. Never substitute or mix oil brands. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary.

U-joint Disassembly – projex inbox.


Wear eye protection when removing snap ring to prevent serious personal injury. Stretch chain tight on a flat surface and sportssman a 10 lb. Cylinder Head Exploded View – projex inbox.

Tire Pressure, Tire Inspection – poalris inbox. Page 13 – projex inbox. Remove cover and diaphragm from master cylinder and dispose of the fluid properly. Make sure all bearings are firmly seated in the crankcase. Measure pump end clearance using a feeler gauge and straight edge. Measure belt length with a tape measure around the outer circumference of the belt.

This manual contains the following sections Find the item you ordered. Carburetor Cleaning – projex inbox. Drive Belt Installation – projex inbox. Stator Plate Bolt Torque: Purge accumulated carbon from the system by momen- Clean Out Plug tarily revving the engine several times. Rear Wheel Nuts 20 Ft. Bent armature plates should be replaced.

Measure piston pin bore.