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Polaris Sportsman 400, 450, 500 WSM 1996-2013 ATV Service Repair Manual 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013
This original Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A manual is a detailed file and it is illustrated with clear step-by-step instructions.
Total Pages 626 and Covers Following Models:
Sportsman 400 (2001-2005)
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 (2006-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
The Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A pdf contains help for troubleshooting and will support you how to fix your problems immediately.
This highly detailed manual is very useful and contains everything you need to repair, service, restore maintain, rebuild or diagnose your Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A.
This Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A manual is the same manual used by professional technicians, mechanics and workshops. - Perfect for all DIY persons!
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This official service, repair guide, factory or workshop manual gives you the complete step by step informations on servicing, repairing and preventative maintenance. It is your essential help guide through every repair and troubleshooting procedure.
Polaris Sportsman 400, 450, 500 WSM 1996-2013 Service Repair Manual for sale
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Total Pages 626 and Covers Following Models: Sportsman 400 (2001-2005) Sportsman 400 HO (2011-2013) Sportsman 450 (2006-2007) Sportsman 450 Browning Edition (2006) Sportsman 500 (1996-2010) Sportsman 500 RSE (2000-2002) Sportsman 500 DUSE (2001-2002) Sportsman 500 HO (2001-2006, 2008-2013) Sportsman 500 X2 (2006-2010) Sportsman Touring 500 (2008-2013) Worker 500 (1997-2001) Xplorer 500 (1997) This manual covers all models with EFI. This manual does not cover 500 ATP HO models. 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 level check / Engine oil and filter change / Oil pump priming / Oil pressure test / Transmission oil level check / Transmission oil change / Front gearcase oil level change / Front gearcase oil change / Front hub (1996-early 2004 models) oil level check / Front hub (1996-early 2004 models) oil change / Clutch draining and drying / Clutch belt inspection / Air filter service / Fuel tank vent hose / Fuel hose inspection / Fuel filter service / Brake system / Control cable lubrication Throttle cable/electronic throttle control (ETC) adjustment / Throttle cable adjustment / Choke cable inspection / Cooling system inspection / Coolant level check / Exhaust system / Suspension / Tires and wheels / Toe-in adjustment alignment / Lubrication service: front suspension arms , front struts, lower end of the steering shaft, front drive axle inner U-joints, front propeller shaft, front U-joints, rear U-joint, upper and lower rear suspension arms, and rear bar stabilizer assembly / 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 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 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
Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A pdf (How to fix...) - This is a specific and detailed pdf manual.
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This Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A manual has been produced by the manufacturer and it offers all informations and instructions for your Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A
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Polaris Sportsman 400, 450, 500 WSM 1996-2013 Service Repair Manual
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This Polaris Sportsman 400, 450, 500 WSM 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013 2013 A manual is digitally delivered, there are no shipping costs.
This is the electronic download versions of the Polaris Sportsman 400, 450, 500 WSM 1996-2013 Service Repair Manual.
Total Pages 626 and Covers Following Models:
Sportsman 400 (2001-2005)
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 (2006-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
This manual covers all models with EFI. This manual does not cover 500 ATP HO models. 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 level check / Engine oil and filter change / Oil pump priming / Oil pressure test / Transmission oil level check / Transmission oil change / Front gearcase oil level change / Front gearcase oil change / Front hub (1996-early 2004 models) oil level check / Front hub (1996-early 2004 models) oil change / Clutch draining and drying / Clutch belt inspection / Air filter service / Fuel tank vent hose / Fuel hose inspection / Fuel filter service / Brake system / Control cable lubrication Throttle cable/electronic throttle control (ETC) adjustment / Throttle cable adjustment / Choke cable inspection / Cooling system inspection / Coolant level check / Exhaust system / Suspension / Tires and wheels / Toe-in adjustment alignment / Lubrication service: front suspension arms , front struts, lower end of the steering shaft, front drive axle inner U-joints, front propeller shaft, front U-joints, rear U-joint, upper and lower rear suspension arms, and rear bar stabilizer assembly / 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 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 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
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