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  Polaris Repair Manual Sportsman 400, Sportsman 450, Sportsman 500, Worker 500, Xplorer 500 1996-2008
  Polaris Repair Manual Sportsman 400, Sportsman 450, Sportsman 500, Worker 500, Xplorer 500 1996-2008
 
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Product Code: CL-M365-3

Features
 
Features
This repair manual covers Polaris Sportsman 400, 450 and 500, Polaris Worker 500 and Polaris Xplorer 500, 1996 through 2008, including:
  • Sportsman 400 (2001-2005)
  • Sportsman 450 (2006-2007)
  • Sportsman 450 Browning Edition (2006)
  • Sportsman 500 (1996-2008)
  • Sportsman 500 RSE (2000-2002)
  • Sportsman 500 DUSE (2001-2002)
  • Sportsman 500 HO (2001-2006, 2008)
  • Sportsman 500 X2 (2006-2008)
  • Sportsman 500 Touring (2008)
  • Worker 500 (1997-2001)
  • Xplorer 500 (1997)
Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: 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

CHAPTER TWO: 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

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Engine oil | Oil pump priming | Oil pressure test | Transmission | Front gearcase oil | Front hub (1996-early 2004 models) | Clutch | Air filter | Fuel tank vent hose | Fuel hose and filter | Brake system | Control cables | Cooling system | Exhaust system | Suspension | Tires and wheels | Lubrication service | Fastener inspection | Valve clearance | Compression test | Spark plug | Ignition timing | Idle speed | Specifications

CHAPTER FOUR: 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

CHAPTER FIVE: ENGINE LOWER END
Engine | Flywheel and stator plate | Recoil starter | Crankcase | Oil pump | Oil system one-way check valve | Break-in procedure | Specifications

CHAPTER SIX: 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

CHAPTER SEVEN: 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

CHAPTER EIGHT: COOLING SYSTEM
Air cooling system | Liquid cooling system | Hoses and hose clamps | Radiator | Cooling fan | Coolant pump | Thermostat | Specifications

CHAPTER NINE: CLUTCH and DRIVE BELT
Clutch system operation | Clutch tools | Clutch drying | Drive belt | Belt alignment | Drive clutch | Driven clutch | Specifications

CHAPTER TEN: TRANSMISSION (1996-EARLY 2004 MODELS)
Transmission | Transmission inspection | Shift shafts | Front output shaft | Transmission gearcase oil seal inspection and replacement | Shift selector linkage | Specifications

CHAPTER ELEVEN: TRANSMISSION (LATE 2004-ON MODELS)
Transmission | Transmission shafts | Differential gear assembly (X2 and Touring models) | Snorkel shaft | Shift selector linkage | Specifications

CHAPTER TWELVE: 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

CHAPTER THIRTEEN: 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

CHAPTER FOURTEEN: FRONT SUSPENSION and STEERING
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
Rear wheel | 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

CHAPTER SIXTEEN: 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

CHAPTER SEVENTEEN: 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.

PRODUCT DETAILS:
  • Publisher: Clymer Manuals - 2008
  • Author: Clymer Staff
  • Binding: Paperback - 7 x 10 inches
  • Pages: 688 - Hundreds of b&w photos and illustrations
  • ISBN: 9781599692425

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