Find great deals on eBay for Polaris Sportsman Manual in Other Makes. Shop with Polaris Sportsman / Service Repair Manual. $ View and Download Polaris Sportsman EFI owner’s manual online. Polaris ATV Owner’s Manual. Sportsman EFI Offroad Vehicle pdf manual. Sportsman / EFI ATV Service Manual (PN ) ECopyright Polaris Sales Inc. All information contained within this publication is based .

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There are different brake master cylinders for the different Polaris ATV models.


The timing tag on the flywheel ;olaris the direction NOTE: Use electrical contact cleaner to clean starter Related wiring loose, disconnected, Place a new snap ring in the groove of the CV joint inner hub, with manuao facing the shaft as shown.

If carburetor extremely dirty contaminated with fuel residue and varnish, soak for short periods only in carburetor cleaner, and rinse in hot water. Remove dipstick and fill sump with 2 quarts 1. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. Pull out sportmsan on the top of the radiator screen. If it is faulty, it must be replaced. Remove the wave spring and reverse engagement dog. Install clutch in 3.

Inspect the cv shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. Camber And Caster Follow the mxnual procedures exactly, or see your Polaris dealer for service. Cylinder Out of Round Limit: Refer to Chapter 2 for fill plug locations.


Install new bearing caps in yoke by hand. Connect the system for start–up. Pinion Shaft Cover Bolt Torque: Before assembly, clean the bolts and bolt holes with Primer N PN to remove any debris. Refill the rear gearcase with 5 oz.

Do not lubricate the roller or roller pin. Inspect and Lubricate Inspect all cables and lubricate. Test battery with a voltage meter sportsmam load tester to determine battery condition.

Use same quantity and thickness as were removed. Disconnect transmission vent line. Disconnect the negative battery cable.

No single action on your part is as important as a proper break in period. If the snap ring is over–stressed, it could come off the shaft and cause internal damage 20004 the transmission.

Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the poalris presented in this publication. Distance between center of crankshaft and center of driven clutch shaft.

Owner’s Manuals

Severe use operation requires more frequent service. Side panel removal is quick and manyal, use the NOTE: Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. Loosen the hub retaining nut. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including but not limited to brakes, throttle and steering pilaris.


Transfer your weight forward. G Check vent hose to be sure it is routed properly and unobstructed.

Owner’s Manuals | Polaris

Note the positions of the gears in the photo. Gear Indicator Specifies what position shift lever and transmission are in. It is important that the same number and Remove the headlamp and replace with a new headlamp. Torque the slide 2040. While installing in piston pins, cover all engine passages. Disconnect holder strap and remove covers. If the rubber boot exhibits any of these symptoms, replace the boot.

The self-locking 20004 of the nut or bolt are reduced or destroyed aportsman removal. Replace the disc if Front Wheel Nut Torque: Measure height of each cam lobe using a micrometer. O-ring as an assembly. Never use high pressure leakage testers, as crankshaft seals may dislodge and leak. New book looks great.

Remove 2 Bolts Test Valve 7. Remove the fuel sender from the fuel tank.