2005 POLARIS SPORTSMAN 400 MANUAL PDF

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Apply and hold downward pressure on the helix, or place driven clutch in compressor tool PN Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge. Use an arbor and press only on sportwman outer race, as bear- ing damage may occur.

Polaris Sportsman 400 Service Manual

Remove flange bolts 10 from magneto side crankcase evenly in a cross pattern. Torque flywheel to specification. Check bearing condition, and snap ring location. Crankshaft End Play Adjustment – projex inbox. Do not force the fluid into the hub under pressure or seal damage may occur.

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Polaris Sportsman Manual | eBay

Install brake pads in caliper body with friction material facing each other. Inspect the bore for nicks, scratches or wear.

Serious injury could occur if machine tips or falls. Do not dilute with water. Transmission Removal – projex inbox. Awd Front Drive Axle Installation – projex inbox. Seal stator wire grommet with 3 Bond or equivalent sealer. Awd Front Hub Exploded View – projex inbox.

Remove all carbon from valve with a soft wire wheel. Be sure to clean seal grooves in caliper body. Stop engine, place machine in gear and set parking brake.

Remove left rear drive shaft see page 7. The mnaual drain screw is located on the bottom left side of the float bowl. Remove bolt securing tensioner blade to crankcase A. Using a digital multitester, measure the resistance between each of po,aris commutator segments. Front Pad Removal – projex inbox. Severe injury may occur if machine tips or falls.

Remove complete airbox assembly transmission vent line. Oil Pump Assembly – projex inbox. Off Season Storage, Charging Procedure – projex inbox. The steering frog can be used as an oolaris of whether the handlebars are straight. Check for current draw with the key 400. Browse Related Browse Related.

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Jetting Guidelines – projex inbox. The spring is a compression spring only and has no torsional wind. Note location of chain tensioner cam. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller.

Mark chain rotation direction for assembly. Refer to the warning tire pressure decal manyal to the vehicle. Start bearing carrier on drive shaft. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary.

Engine Service Data – projex inbox. There should not be any binding or rough spots. Inspect cylinder for wear, scratches, or damage. This manual will sporteman Carefully pull the gear shift selector cover and rod from the gear shift selector body.

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