DOWNLOAD Polaris Sportsman Repair Manual 400 450 500 550 600 700 800 850

DOWNLOAD Polaris Sportsman Repair Manual 400 450 500 550 600 700 800 850 Service Manual Workshop Guide

Downloadable Polaris Sportsman all-terrine vehicle repair manuals are digitally transferred repair books that can be transmitted from one computer to another. Polaris Sportsman repair books are digitally delivered instruction guides developed and distributed to certified dealership technicians, professionally trained mechanics or anyone who wants to repair their off-road 4-wheeler themselves. 

Polaris Sportsman four-wheeler repair manuals cover every aspect of service and repair. Wether you’re adjusting the idle speed, installing new piston rings or rebuilding the entire engine, a Polaris Sportsman repair manual covers it all. Critical specifications, advanced troubleshooting guides, pictures, schematics and diagrams are included in the manuals to ensure the mechanic complete the repair job successfully. Here’s a small list of subjects covered in a repair manual (topics may differ depending on year and model):

DOWNLOAD Polaris Sportsman Repair Manual 400 450 500 550 600 700 800 850 Service Manual Workshop Guide

General Information

  • Model number information
  • Serial number locations
  • Machine dimensions
  • Vehicle specifications
  • Paint codes
  • Standard torque specifications
  • Tap drill charts
  • Decimal equivalent chart
  • Conversion table

Engine

  • Engine exploded views
  • Torque specifications
  • Engine torque patterns
  • Engine service data
  • Piston identification
  • Troubleshooting
  • Engine lower disassembly and assembly
  • Camshaft inspection
  • Flywheel/stator removal and inspection
  • Flywheel/stator installation
  • Stator bendix removal and inspection
  • Piston, piston rod, piston ring service
  • Cylinder inspection
  • Piston removal and installation
  • Cooling system specifications
  • Cooling system pressure tests
  • Valve lifter removal and inspection
  • Cylinder removal
  • Engine head disassembly and reassembly
  • Valve inspection
  • Rocker arm/pushrod checking
  • Cylinder honing
  • Oil flow chart
  • Engine removal
  • Engine installation

Body, Steering And Suspension

  • Body assembly, exploded view
  • Headlight pot exploded view
  • Decal replacement
  • Front strut ball joint replacement
  • Front struct cartridge replacement
  • Steering post assembly
  • Steering/a-arm exploded view
  • Rear suspension exploded view
  • Front struct assembly exploded view
  • Torque specifications
  • Side panel removal
  • A-arm replacement
  • Steering post assembly

Transmission Service

  • Transmission exploded view
  • Torque specifications and lubricants
  • Gear shift selector removal
  • Transmission removal
  • Transmission disassembly and assembly
  • Transmission installation

Brakes

  • Torque specifications
  • Brake system service notes
  • Front and rear caliper exploded view
  • Brake noise troubleshooting
  • Hydraulic brake system overview
  • Hydraulic caliper bleeding
  • Brake bleeding and fluid change
  • Rear axillary master cylinder exp. view
  • Front and rear disc brake inspection
  • Front and rear disc brake removal
  • Front and rear disc brake instillation
  • Front and rear caliper removal and install
  • Front and rear caliper exploded view
  • Brake burnishing
  • Master cylinder removal and install

Electrical

  • Alternator exploded view
  • Wiring diagrams
  • Starter system testing flow chart
  • Starter assembly exploded view
  • Starter drive
  • Starter system troubleshooting
  • Starter testing
  • Flywheel identification
  • Timing check procedure
  • Trigger coil cap
  • Transmission gear position switch test
  • Instrument cluster troubleshooting
  • Headlight, brake light lamp service
  • Battery activation service
  • Speedometer removal and install
  • Speedometer troubleshooting
  • Coolant sensor test
  • Charging system testing
  • CDI output tests
  • Ignition system troubleshooting
  • Ignition system testing flow chart
  • Fan motor test
  • Fan control switch test
  • Electronic throttle circuit system

Maintenance

  • Periodic maintenance chart
  • Recommended lubricants and capacities
  • Special tools
  • Lubrication charts
  • Tire inspection
  • Wheel removal and installation
  • Front and rear gearcase lubrication
  • Controls
  • Suspension service
  • Brake system service
  • Transmission lubrication
  • Transmission linkage check
  • Carburetor adjustment and tune-up
  • Exhaust system maintenance
  • Steering and toe alignment
  • Fuel system
  • Compression test
  • Battery maintenance
  • Electrical
  • Oil change/filter
  • PVT drying and PVT drain plug
  • Breather filter
  • Coolant system maintenance
  • Radiator screen removal
  • Air box sediment tube service
  • Air filter service
  • Fuel injection service
  • Fuel lines
  • Throttle inspection
  • Throttle cable adjustment
  • Fuel filter
    Electronic throttle control

Fuel System

  • Exploded view carburetor
  • Fuel tank assembly exploded view
  • Fuel flow system diagram
  • Carburetor jetting guidelines
  • Carburetor jetting
  • Main jet / pilot jet part numbers
  • Carburetor disassembly and cleaning
  • Carburetor assembly and instillation
  • Carburetor tune-up
  • Float adjustment
  • Needle and seat leakage test
  • Fuel level
  • Fuel pump service
  • Troubleshooting
  • Electronic fuel injection
  • EFI service notes
  • EFI system exploded view
  • Electronic control module (ECM)
  • Fuel pump test
  • Fuel pump / tank assembly replacement
  • Fuel pressure regulator
  • Fuel filters
  • Fuel injectors
  • Crankshaft position sensor (CPS)
  • Manifold air pressure sensor (MAP)
  • Intake air temperature sensor (IAT)
  • Idle air control (IAC)
  • Throttle position sensor (TPS)
  • Engine temperature sensor
  • Fuel system troubleshooting
  • EFI diagnostics using blink codes
  • Troubleshooting diagrams

Final Drive

  • AWD axle/propshaft exploded view
  • Torque specifications
  • Front and rear hub inspection
  • Front drive axle removal and install
  • Driveshaft and CV joint handling tips
  • Front and rear driveshaft CV boot replacement
  • Front and rear hub disassembly and assembly
  • AWD front prop shaft removal
  • Front and rear gearcase removal
  • Front and rear gear case disassembly
  • Front and rear gearcase assembly and install
  • Front and rear gear case exploded view

PVT System

  • Drive clutch exploded view
  • PVT sealing and ducting components
  • EBS system exploded view
  • PVT operation overview
  • PVT Maintenance and inspection
  • PVT overheating and diagnosis
  • PVT disassembly and assembly
  • Drive clutch bushing service
  • Drive clutch spring specs
  • Driven one-way clutch inspection
  • Shot weights and inspection
  • Clutch alignment and offset
  • Drive clutch disassembly and reassembly
  • Troubleshooting

Download a Polaris Sportsman repair manual in seconds and fix your quad runner now. These repair manuals are identical to the repair manuals you'd obtain in a book store. They cover ever aspect of maintenance, troubleshooting and repair. It's the only manual you should be using if you plan to perform service or repairs to your Sportsman four-wheeler. 

7 Comments

  1. I have a 1992 1/2 Sportsman Polaris 4 x4 and need a parts diagram. Does the manual contain this diagram?

    • Yes, there is a download manual for the 2004 Sportsman 400. Here’s a small list of four-wheelers you can download a manual for:

      2009 Polaris Sportsman XP 550
      2009 Polaris Sportsman 90
      2005 Polaris Sportsman 500
      2004 Polaris Sportsman Late Sportsman 600
      2000 Polaris Sportsman 335 4X4
      2003 Polaris Sportsman 90
      2008 Polaris Sportsman X2 700 EFI
      2009 Polaris Sportsman X2 800 EFI
      2009 Polaris Sportsman 500 H.O.
      2005 Polaris Sportsman 400
      2009 Polaris Sportsman XP550 EPS
      2003 Polaris Sportsman 700
      2004 Polaris Sportsman Early Sportsman 700
      2009 Polaris Sportsman 800 EFI
      2004 Polaris Sportsman Late Sportsman 700
      2002 Polaris Sportsman 700
      2005 Polaris Sportsman 700 EFI
      1994 Polaris Sportsman 4X4
      2007 Polaris Sportsman 500 EFI
      2012 Polaris Sportsman 400 H.O.
      1998 Polaris Sportsman 500
      2009 Polaris Sportsman 300
      1996 Polaris Sportsman 500
      2009 Polaris Sportsman 800 6X6 EFI
      1999 Polaris Sportsman 500 4X4
      2005 Polaris Sportsman 800 EFI
      2012 Polaris Sportsman 500 H.O.
      2009 Polaris Sportsman Touring 500 EFI
      2009 Polaris Sportsman XP 850 EPS
      1995 Polaris Sportsman 4X4
      1999 Polaris Sportsman 335 4X4
      1993 Polaris Sportsman
      2007 Polaris Sportsman 500 X3 EFI
      2009 Polaris Sportsman 400 H.O.
      2007 Polaris Sportsman 800 EFI
      2009 Polaris Sportsman 500 EFI
      2012 Polaris Sportsman Forest Tractor 500 EFI
      2004 Polaris Sportsman 90
      2001 Polaris Sportsman 90
      2009 Polaris Sportsman Touring 800 EFI
      2000 Polaris Sportsman 500 RSE 4X4
      2000 Polaris Sportsman 500 4X4
      2008 Polaris Sportsman Touring 800 EFI
      2009 Polaris Sportsman 90
      2009 Polaris Sportsman X2 500 EFI
      1997 Polaris Sportsman 400 4X4 400 L
      2008 Polaris Sportsman 800 EFI
      2004 Polaris Sportsman Early Sportsman 600
      2009 Polaris Sportsman XP 850
      2007 Polaris Sportsman 450 EFI
      2012 Polaris Sportsman Touring 500 HO
      2007 Polaris Sportsman 700 EFI
      1997 Polaris Sportsman 500
      2000 Polaris Sportsman 500 6X6
      2008 Polaris Sportsman 500 EFI
      2007 Polaris Sportsman X2 800 EFI
      2008 Polaris Sportsman X-2 500 EFI
      1996 Polaris Sportsman 4X4 400L
      2008 Polaris Sportsman 500
      2003 Polaris Sportsman 600

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