Polaris sportsman 400 500 service repair manual 2003 2004. Workshop Manuals, Service, Car Repair, Haynes Manuals Online Download 2019-03-21

Polaris sportsman 400 500 service repair manual 2003 2004 Rating: 5,3/10 1163 reviews

POLARIS SPORTSMAN 400 SERVICE MANUAL Pdf Download.

polaris sportsman 400 500 service repair manual 2003 2004

Refer to the warning tire pressure decal applied to the vehicle. The manual has detailed illustrations, diagrams, wiring schematics and specifications as well as step-by-step instructions. Remove driven clutch offset spacers from the transmission input shaft. Install caliper and torque the mounting bolts. Force U-joint cross to one side and lift out of inner yoke. Remove nut from puller rod and set aside. Remove float bowl and carefully remove the keeping.

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Workshop Manuals, Service, Car Repair, Haynes Manuals Online Download

polaris sportsman 400 500 service repair manual 2003 2004

There should not be any binding or rough spots. Apply electrical tape to threads of housing to prevent damage. If anti-tamper plug is installed in pilot screw cavity, refer to Maintenance chapter 2 for removal procedure. Upon disassembly, place the parts in a container for safe 2. Remove fill check plug and rotate hole to either 4:00 or 8:00 position. The needle and seat should hold pressure indefinitely. Rocker Shaft Support Tower Bolt Torque: 9 ft.

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Polaris : Service And Repair Manuals

polaris sportsman 400 500 service repair manual 2003 2004

Seal Retaining Ring Shim s Bearing Housing Shaft 27. Install drive shaft in strut. Inspect jet needle and needle jet for wear. Always use genuine Polaris parts. Rpm runs high and low inter changes.

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1996

polaris sportsman 400 500 service repair manual 2003 2004

A gritty feeling indicates contamination. Two harnesses plug into the cluster head;. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Do not apply oil or grease to the bushings. Slide prop shaft back and away from front housing. One must always be installed.

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POLARIS SPORTSMAN 400 SERVICE MANUAL Pdf Download.

polaris sportsman 400 500 service repair manual 2003 2004

Reconnect linkage rods to gear shift selector slides. Always stop the engine and refuel outdoors or in a well ventilated area. Inspect the drained fuel for water or sediment. Continue to screw front housing in, making sure O-ring enters housing without damage. Visually inspect disc for scoring, scratches, or gouges. Hold reel firmly in housing.

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POLARIS SPORTSMAN 400 2003 SERVICE MANUAL Pdf Download.

polaris sportsman 400 500 service repair manual 2003 2004

Remove chain tensioner along with mounting pins 8. Connect an ammeter in series with the negative battery cable. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. Be sure vents in cover are clean and unobstructed. Inspect center shaft bushing for wear.

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POLARIS SPORTSMAN 400 SERVICE MANUAL Pdf Download.

polaris sportsman 400 500 service repair manual 2003 2004

Remove inner and outer feed rotor and pump chamber body. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. Cotter Pin ยก Castle Nut Use new cotter pin O-Ring Bearing Race Washer. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading. To correct a situation like the one shown in the. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. Replace chain and chain tensioner shoe.

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1996

polaris sportsman 400 500 service repair manual 2003 2004

Some solvents may leave a residue or damage inter- nal parts and insulation. Oil Pipe Bolt Torque: 20 ft. Stator Plate Bolt Torque: 5. Apply Polaris Premium Starter Drive grease to the camshaft main journals and cam lobes. Support bottom of bearing carrier housing. The actuator ball in the camshaft is not replaceable.

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Polaris

polaris sportsman 400 500 service repair manual 2003 2004

Mark chain rotation direction for assembly. Note the alignment marks on both ends of the starter motor casing. The other numbers are used for identification as to diameter, length and design. Compression readings will vary in pro- portion to cranking speed during the test. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced cooling. Remove 2 bolts holding pump drive gear C.

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