2009 Polaris Sportsman 300 2X4 Service Repair Manual by 163633

GENERAL INFORMATION

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL: 2009 SPORTSMAN 300 / 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 DETAILED: 2009 SPORTSMAN 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2009 SPORTSMAN 400 H.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

1.1

GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification

27 AA

} } }

}

A 0 9 LH

Emissions & Model Option

Year Designation Basic Chassis Designation

Engine Designation

Engine Designation Number ES300PFE .......................................................... Single, Air Cooled, SOHC 4 Stroke, Electric Start EH460PLE ..................................................... Single, Liquid Cooled, SOHC 4 Stroke, Electric Start

Vehicle Identification Number (VIN) World Mfg. ID

Vehicle Identifier

Vehicle Descriptor

4 5 6 7 8 9 10 11 12 13 14 15 16 17 L H 2 7 A * 9 P 0 0 0 0 0 0 Engine

Body Style

}

1 2 3 4 X A

Model Year

Individual Serial Number

Plant No Emissions Powertrain Check Digit

* This could be either a number or a letter

Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number is stamped on the center top of the crankcase beneath the cylinder and is also located on the sticker applied to the recoil housing on the right side of engine (see Figure 1-2). Figure 1-2

Figure 1-1

VIN

1.2

Engine Serial Number

GENERAL INFORMATION SPECIFICATIONS

MODEL: 2009 SPORTSMAN 300 MODEL NUMBER: . . . . . . . . .A09LH27AX, A09LH27AZ ENGINE MODEL: . . . . . . . . . .ES300PFE012 Category

Dimension

Length

74 in. / 188 cm

Width

42 in. / 107 cm

Height

45.5 in. / 116 cm

Wheel Base

46 in. / 117 cm

Dry Weight

550 lbs. / 250 kg

Gross Vehicle Weight

915 lbs. / 415 kg

Front Rack Capacity

70 lbs. / 31.75 kg

Rear Rack Capacity

100 lbs. / 45 kg

Towing Capacity

750 lbs. / 340 kg

Max. Weight Capacity

365 lbs. / 166 kg

Hitch Tongue Weight

75 lbs. / 34 kg

MODEL: 2009 SPORTSMAN 400 H.O. MODEL NUMBER: . . . . . . . . .A09LH46AQ, A09LH46AX, A09LH46AZ ENGINE MODEL: . . . . . . . . . .EH460PLE020 Category

Dimension

Length

73 in. / 185 cm

Width

44 in. / 112 cm

Height

46 in. / 117 cm

Wheel Base

46 in. / 117 cm

Dry Weight

598 lbs. / 271 kg

Gross Vehicle Weight

963 lbs. / 437 kg

Front Rack Capacity

70 lbs. / 32 kg

Rear Rack Capacity

100 lbs. / 45 kg

Towing Capacity

750 lbs. / 340 kg

Max. Weight Capacity

365 lbs. / 166 kg

Hitch Tongue Weight

75 lbs. / 34 kg

1.3

GENERAL INFORMATION MODEL: 2009 SPORTSMAN 300 MODEL NUMBER:........... A09LH27AX, AZ ENGINE MODEL:............. ES300PFE012 Engine Platform

Fuji 4-cycle, A/C, Single Cyl.

Engine Model Number

ES300PFE012

Engine Displacement

299cc

Number of Cylinders

Bore & Stroke (mm)

77.7 x 63 mm

Compression Ratio

9.2:1

Compression Pressure Engine Idle Speed Cooling System

PS-4 Plus / 1.7 qt. (1.6 L)

Exhaust System

Single Pipe - USFS Approved Mikuni BST 34mm

Clutch Type

CVT w/EBS

Belt

3211108 Steering / Suspension

45 / 140

Jet Needle

4HC57-3

Needle Jet

0-5M

Pilot / Air Screw

2.5 Turns Out (Initial setting)

Float Height

13mm from carburetor body

Fuel Delivery

Fuel Pump (Impulse)

Fuel Capacity

4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated

Rear Suspension / Shock

8 in. / 20.3 cm

Ground Clearance

8 in. / 20.3 cm

Shock Preload Adjustment Front / Rear

Voltage Regulator

3-Phase 20 Amp

Head Lights

12V / 37.5 watts

Brake Light

12V / 26.9 watts

Tail Light

12V / 8.26 watts

Ignition System

DC / CDI

Ignition Timing

10° ± 2° BTDC @ 1500 RPM 30° ± 2° BTDC @ 5000 RPM

Spark plug / Gap

NGK CR8E / .031 in. (.8 mm)

Starting Indicator Panel

1.4

Cam Adjustable 62.5 in. (159 cm) unloaded

Toe Out

0-1/16 in. (0-.159 mm) Wheels / Brakes

Front Wheel Size Front Tire Model / Size

12x5 Maxxis AT / 22 x 7-12

Rear Wheel Size Rear Tire Model / Size

12x8 Maxxis AT / 22 x 10-12

Tire Air Pressure - F / R

5 psi (34.5 kPa) Single Control Hydraulic Disc

Brakes - Front & Rear Brake Fluid

Polaris DOT 4 Brake Fluid

JETTING CHART AMBIENT TEMPERATURE

250 watt @ 6000 RPM

Circuit Breakers

IRS / Progressive Rate

Rear Travel

Electrical Alternator Output

Battery / Model / AH

MacPherson Strut 7 in. / 17.8 cm

140

Pilot Jet / Pilot Air Jet

Fuel Requirement (Octane)

Front Output Fwd 5.17:1 / Rev 4.79:1 Rear Output Fwd 15.18:1 / Rev 14.05:1

Turning Radius

Carburetion Main Jet

Gear Ratio :

1400 RPM

Oil Requirements

Polaris Premium AGL / 20.3 oz. (592 ml)

Front Gearcase Fluid Type Polaris Demand Drive Hub / Fluid Capacity Fluid / 5 oz. (148 ml)

Front Travel

Wet Sump

Carburetor model

Transmission Fluid Type / Fluid Capacity

Front Suspension / Shock

None

Lubrication

In-Line F-N-R

120-140 psi Air / Oil Cooled

Overheat Warning

Drivetrain Transmission Type

ALTITUDE Meters (Feet) 0-900 (0-3000)

Electric / Recoil Back-up LCD / Indicator lights

Above +40° F Above +5° C

145

140

900-1800 (3000-6000)

Same main jet / Remove 2 air box plugs

1800-2700 (6000-9000)

Same main jet / Remove 4 air box plugs

Above 2700 (Above 9000)

Same main jet / Remove 6 air box plugs Move jet needle clip to position #2

CLUTCH CHART ALTITUDE

Yuasa / YB14-B2 / 14 AH 15A - Accessory / 15A - Main Harness

Below 40° F Below 5° C

Meters (Feet)

SHIFT WEIGHT

# INSTALLED

0-1500 (0-5000)

13 g 5412988

1500-3000 (5000 - 10000)

10 g 5412986

3000 + (10000 +)

10 g 5412986

*Note: Remove opposite rollers to retain proper clutch balance

GENERAL INFORMATION MODEL: 2009 SPORTSMAN 400 H.O. MODEL NUMBER: .... A09LH46AQ, AX, AZ ENGINE MODEL: ...... EH460PLE020 Engine Platform

Fuji 4-cycle, L/C, Single Cyl.

Engine Model Number

EH460PLE020

Engine Displacement

455cc

Number of Cylinders

Bore & Stroke (mm)

87.9 x 75 mm

Compression Ratio

10.1:1

Compression Pressure

50-90 psi

Engine Idle Speed

1375 RPM

Cooling System / Cap. Overheat Warning

Liquid / 2.2 qt. (2 L) LCD / Red Indicator Light

Lubrication

Dry Sump

Oil Requirements

PS-4 Plus / 2 qt. (1.9 L)

Exhaust System

Single Pipe - USFS Approved Mikuni BST 34mm

Main Jet

42.5 / 160

Jet Needle

4IB33-3

Needle Jet

P-6M

Pilot / Air Screw

2.75 Turns Out (Initial setting)

Float Height

13mm from carburetor body

Fuel Delivery

Fuel Pump (Impulse)

Fuel Capacity / Fuel Requirement (Octane)

Transmission Fluid Type / Fluid Capacity

4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated

Gear Ratio :

Front Output Fwd 5.17:1 / Rev 4.79:1 Rear Output Fwd 15.18:1 / Rev 14.05:1

Clutch Type

CVT w/EBS

Belt

3211129 Steering / Suspension

Front Suspension / Shock

7 in. / 17.8 cm

Rear Suspension / Shock

IRS / Progressive Rate

Rear Travel

8 in. / 20.3 cm

Ground Clearance

9 in. / 22.9 cm

Shock Preload Adjustment Front / Rear

Cam Adjustable 69 in. (175 cm) unloaded

Toe Out

0-1/16 in. (0-.159 mm) Wheels / Brakes

Front Wheel Size Front Tire Model / Size

12x5 Titan 489 / 24 x 8-12

Rear Wheel Size Rear Tire Model / Size

12x8 Titan 489 / 24 x 11-12

Tire Air Pressure - F / R

5 psi (34.5 kPa) Single Control Hydraulic Disc

Brakes - Front & Rear Brake Fluid

Polaris DOT 4 Brake Fluid

JETTING CHART AMBIENT TEMPERATURE

Alternator Output

250 watt @ 6000 RPM

Voltage Regulator

3-Phase 20 Amp

Head Lights

12V / H-35 watts, L-35 watts

Brake Light

12V / 26.9 watts

Tail Light

12V / 8.26 watts

Ignition System

DC / CDI

Ignition Timing

14° ± 2° BTDC @ 1500 RPM 30° ± 2° BTDC @ 5000 RPM

Spark plug / Gap

NGK BKR6E / .035 in. (.9 mm)

Battery / Model / AH

Yuasa / YTX14AH-BS / 12 AH

Circuit Breakers

10A - Accessory / 10A - Fan / 15A - Main Harness

Indicator Panel

MacPherson Strut

Front Travel

Electrical

Starting

Polaris Premium AGL / 20.3 oz. (592 ml)

Front Gearcase Fluid Type Polaris Demand Drive Hub / Fluid Capacity Fluid / 5 oz. (148 ml)

157.5

Pilot Jet / Pilot Air Jet

In-Line F-N-R

Turning Radius

Carburetion Carburetor model

Drivetrain Transmission Type

ALTITUDE

Meters (Feet)

Below 40° F Below 5° C

Above +40° F Above +5° C

0-1800 (0-6000)

162.5

157.5

1800-3700 (6000-12000)

150

145

CLUTCH CHART ALTITUDE

Meters (Feet)

SHIFT WEIGHT

# INSTALLED

0-1500 (0-5000)

19.5 g 5413447

1500-3000 (5000 - 10000)

17 g 5412975

3000 + (10000 +)

16 g 5412991

Electric / Recoil Back-up LCD / Indicator lights

1.5

GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers YEAR

MODEL

MODEL NO.

OWNER’S MANUAL PN

PARTS MANUAL PN

2009

SPORTSMAN 300

A09LH27AX, AZ

9921818

9921819

2009

SPORTSMAN 400 H.O.

A09LH46AQ, AX, AZ

9921822

9921823

NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.

Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.

Series #

Part Number

4010278

4010321

4110141

4110148

4010278

Special Tools Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/.

1.6

GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS

Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to the exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size

Threads/In

#10 #10

Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) 24. . . . . . . . . . . . . . . . .27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . .60 (6.9) 32. . . . . . . . . . . . . . . . .31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . .68 (7.8)

1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2

Torque ft. lbs. (Nm)* 20. . . . . . . . . . . . . . . . .5 (7) . . . . . . . . . . . 8 (11) . . . . . . . . . .12 (16) 28. . . . . . . . . . . . . . . . .6 (8) . . . . . . . . . . . 10 (14) . . . . . . . . .14 (19) 18. . . . . . . . . . . . . . . . .11(15) . . . . . . . . . . 17 (23) . . . . . . . . .25 (35) 24. . . . . . . . . . . . . . . . .12(16) . . . . . . . . . . 19 (26) . . . . . . . . .29 (40) 16. . . . . . . . . . . . . . . . .20(27) . . . . . . . . . . 30 (40) . . . . . . . . .45 (62) 24. . . . . . . . . . . . . . . . .23(32) . . . . . . . . . . 35 (48) . . . . . . . . .50 (69) 14. . . . . . . . . . . . . . . . .30(40) . . . . . . . . . . 50 (69) . . . . . . . . .70 (97) 20. . . . . . . . . . . . . . . . .35(48) . . . . . . . . . . 55 (76) . . . . . . . . .80 (110) 13. . . . . . . . . . . . . . . . .50(69) . . . . . . . . . . 75 (104) . . . . . . . .110 (152) 20. . . . . . . . . . . . . . . . .55(76) . . . . . . . . . . 90 (124) . . . . . . . .120 (166)

Metric / Torque 6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25

14-18 ft.lbs . . . . 10 x 1.25

26-30 ft.lbs.

1.7

GENERAL INFORMATION SAE Tap Drill Sizes Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64

Decimal Equivalents Thread Size / Drill Size 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4

1/64 3/64 5/64 7/64 9/64 11/64 13/64 15/64 17/64 19/64 21/64 23/64 25/64 27/64 29/64 31/64 33/64 35/64 37/64 39/64

Metric Tap Drill Sizes Tap Size

Drill Size

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11x1.50 12x1.50 12x1.75

#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

1.8

41/64 Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406

Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64

................. 1/32 . . . . . . . . . . . . . ................. 1/16 . . . . . . . . . . . . . ................. 3/32 . . . . . . . . . . . . . ................. 1/8 . . . . . . . .1250 ................. 5/32 . . . . . . . . . . . . . ................. 3/16 . . . . . . . . . . . . . ................. 7/32 . . . . . . . . . . . . . ................. 1/4 . . . . . . . .25 ................. 9/32 . . . . . . . . . . . . . ................. 5/16 . . . . . . . . . . . . . ................. 11/32 . . . . . . . . . . . . ................. 3/8 . . . . . . . .375 ................. 13/32 . . . . . . . . . . . . ................. 7/16 . . . . . . . . . . . . . ................. 15/32 . . . . . . . . . . . . ................. 1/2 . . . . . . . .5 ..... ................. 17/32 . . . . . . . . . . . . ................. 9/16 . . . . . . . . . . . . . ................. 19/32 . . . . . . . . . . . . ................. 5/8 . . . . . . . .625 ... ................. 21/32 . . . . . . . . . . . . ................. 11/16 . . . . . . . . . . . . ................. 23/32 . . . . . . . . . . . . ................. 3/4 . . . . . . . .75 ................. 25/32 . . . . . . . . . . . . ................. 13/16 . . . . . . . . . . . . ................. 27/32 . . . . . . . . . . . . ................. 7/8 . . . . . . . .875 ................. 29/32 . . . . . . . . . . . . ................. 15/16 . . . . . . . . . . . . ................. 31/32 . . . . . . . . . . . . ................. 1 . . . . . . . . . 1.0

.0156 .0312. . . 1 mm= .0394" .0469 .0625 .0781. . . 2 mm = .0787" .0938 .1094. . . 3 mm =.1181" .1406 .1563. . . 4 mm = .1575" .1719 .1875. . . 5mm= .1969" .2031 .2188 .2344. . . 6 mm = .2362" .2656. . . 7 mm = .2756" .2813 .2969 .3125. . . 8mm= .3150" .3281 .3438. . . 9 mm = .3543" .3594 .3906. . . 10 mm = .3937" .4063 .4219. . . 11 mm =.4331" .4375 .4531 .4688. . . 12 mm = .4724" .4844 . . . . . . . 13mm = .5118" .5156 .5313 .5469. . . 14 mm = .5512" .5625 .5781. . . 15 mm = .5906" .5938 .6094 . . . . . . . 16mm=. 6299" .6406 .6563. . . 17 mm =.6693" .6719 .6875 .7031. . . 18 mm = .7087" .7188 .7344. . . 19 mm = .7480" .7656 .7813. . . 20 mm = .7874" .7969 .8125. . . 21 mm =.8268" .8281 .8438 .8594. . . 22 mm = .8661" .8906. . . 23 mm = .9055" .9063 .9219 .9375. . . 24 mm = .9449" .9531 .9688. . . 25 mm = .9843" .9844

GENERAL INFORMATION Conversion Table Unit of Measure

Multiplied by

ft. lbs.

x 12

= in. lbs.

in. lbs.

x .0833

= ft. lbs.

ft. lbs.

x 1.356

= Nm

in. lbs.

x .0115

= kg-m

x .7376

= ft. lbs.

kg-m

x 7.233

= ft. lbs.

kg-m

x 86.796

= in. lbs.

kg-m

x 10

= Nm

in.

x 25.4

=mm

x .03937

= in.

in.

x 2.54

= cm

mile (mi.)

x 1.6

= km

x .6214

= mile (mi.)

Ounces (oz.)

x 28.35

= Grams (g)

Fluid Ounces (fl. oz.)

x 29.57

= Cubic Centimeters (cc)

Cubic Centimeters (cc)

x .03381

= Fluid Ounces (fl. oz.)

Grams (g)

x 0.035

= Ounces (oz.)

lb.

x .454

= kg

x 2.2046

= lb.

Cubic inches (cu. in)

x 16.387

= Cubic centimeters (cc)

Cubic centimeters (cc)

x 0.061

= Cubic inches (cu. in)

Imperial pints (Imp pt.)

x 0.568

= Liters (l)

Liters (l)

x 1.76

= Imperial pints (Imp pt.)

Imperial quarts (Imp qt.)

x 1.137

= Liters (l)

Liters (l)

x 0.88

= Imperial quarts (Imp qt.)

Imperial quarts (Imp qt.)

x 1.201

= US quarts (US qt.)

US quarts (US qt.)

x 0.833

= Imperial quarts (Imp qt.)

US quarts (US qt.)

x 0.946

= Liters (l)

Liters (l)

x 1.057

= US quarts (US qt.)

US gallons (US gal)

x 3.785

=Liters (l)

Liters (l)

x 0.264

= US gallons (US gal)

Pounds - force per square inch (psi)

x 6.895

= Kilopascals (kPa)

Kilopascals (kPa)

x 0.145

= Pounds - force per square inch (psi)

Kilopascals (kPa)

x 0.01

= Kilograms - force per square cm

Kilograms - force per square cm

x 98.1

= Kilopascals (kPa)

π(3.14)xR x H (height) 2

Converts to

= Cylinder Volume

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

1.9

GENERAL INFORMATION Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.10

MAINTENANCE

CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.8

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 HANDLEBAR COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 THROTTLE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 ELECTRONIC THROTTLE CONTROL SWITCH (ETC) /THROTTLE CABLE ADJUSTMENT2.12 CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PILOT SCREW LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PILOT SCREW AND IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR FILTER / PRE-FILTER SERVICE (300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR FILTER / PRE-FILTER SERVICE (400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL AND FILTER CHANGE (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 ENGINE OIL AND FILTER CHANGE (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . 2.19 OIL PUMP PRIMING PROCEDURE (SPORTSMAN 400 H.O.). . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER FILTER (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER FILTER (SPORTSMAN 400 H.O.). . . . . . . . . . . . . . . . . . . . . . . . 2.21 VALVE CLEARANCE (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 VALVE CLEARANCE (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 EXHAUST SILENCER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 ENGINE MOUNT FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

TRANSMISSION / FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.1

MAINTENANCE COOLING SYSTEM (400 H.O.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

CVT / FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BATTERY REMOVAL (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY INSTALLATION (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY REMOVAL (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY INSTALLATION (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TOE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 BRAKE PEDAL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39

2.2

MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Break-In Period The break-in period consists of the first 20 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. • Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle. • Pull only light loads. • Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist. • Change both the engine oil and filter after 20 hours or one month. • See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance:  = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.

= SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE Maintenance Intervals Maintenance Interval (whichever comes first)

Item

Remarks

Hours

Calendar

Miles (KM)

 Steering

Pre-Ride

 Front Suspension  Rear Suspension

Pre-Ride

 Brake Fluid Level  Brake Lever Travel

Pre-Ride

Brake System

Pre-Ride

Wheels / Fasteners

Pre-Ride

Frame Fasteners

Pre-Ride

Daily

Inspect;clean often

Daily

Drain deposits when visible

Coolant (if applicable)

Daily

Check level daily, change coolant every 2 years

Head Lights / Tail Lights

Daily

Check operation; apply dielectric grease if replacing

 Air Filter (main element)

Weekly

Inspect; replace as needed

Weekly

Drain water as needed, check often if operating in wet conditions

10 H

Monthly

100 (160)

Inspect periodically

20 H

Monthly

200 (320)

Check terminals; clean; test

20 H

25 H

Monthly

250 (400)

Inspect level; change yearly

25 H

Monthly

250 (400)

Inspect level; change yearly

25 H

Monthly

250 (400)

Inspect; replace if necessary

50 H

500 (800)

Lubricate all grease fittings, pivots, cables, etc.

50 H

500 (800)

Drain bowl periodically and prior to storage

50 H

500 (800)

Inspect; adjust; lubricate; replace if necessary

Tires

 Engine Oil Level  Air Filter, Pre-filter E

 Air Box Sediment Tube E

Recoil Housing (if equipped)

 Brake Pad Wear 

Battery

 Engine Oil Change E

(Break-in Period)

 Front Gearcase Fluid  Transmission Lubricant  Engine Breather Filter E (if equipped)

 General Lubrication Carburetor Float Bowl  Throttle Cable / E ETC Switch

Inspect and make adjustments as needed. See Pre-Ride Checklist later in this chapter.

Perform a break-in oil change at one month

Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.4

MAINTENANCE Maintenance Interval (whichever comes first)

Item

Remarks

Hours

Calendar

Miles (KM)

50 H

500 (800)

Inspect; adjust; lubricate; replace if necessary

Carburetor air intake ducts / intake flange

50 H

500 (800)

Inspect ducts for proper sealing / air leaks

Drive belt

50 H

500 (800)

Inspect; adjust; replace as needed

Cooling System (if applicable)

50 H

500 (800)

Inspect coolant strength seasonally; pressure test system yearly

 Engine Oil Change

100 H

1000 (1600)

Perform a break-in oil change at 20 hours or after one month of operation; change more frequently during cold weather operation

 Engine Oil Filter Change 100 H

1000 (1600)

Replace with oil change

 Choke Cable E E

Oil Tank Vent Hose

 (if equipped)

100 H

1000 (1600)

Inspect routing and condition

 Valve Clearance E

100 H

12 M

1000 (1600)

Inspect; adjust

 Fuel System / Fuel Filter 100 H E

12 M

1000 (1600)

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor, replace lines every two years

100 H

12 M

1000 (1600)

Inspect; clean external surfaces

100 H

12 M

1000 (1600)

Inspect for leaks

100 H

12 M

1000 (1600)

Inspect

100 H

12M

1000 (1600)

Inspect

 Spark Plug E

100 H

12M

1000 (1600)

Inspect; replace as needed

 Ignition Timing E

100 H

12M

1000 (1600)

Inspect

 Wiring

100 H

12M

1000 (1600)

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Clutches (Drive and Driven)

100 H

12M

1000 (1600)

Inspect;clean; replace worn parts

 Front Wheel Bearings

100 H

12M

1000 (1600)

Inspect; replace as needed

Radiator

 (if applicable) Cooling Hoses

 (if applicable)  Engine Mounts Exhaust Pipe / Silencer



 Brake Fluid Spark Arrestor

200 H

24M

2000 (3200)

Change every two years

300 H

36M

3000 (4800)

Clean out

Idle Speed

Adjust as needed

 Toe Adjustment

Inspect periodically; adjust when parts are replaced

Adjust as needed

Headlight Aim

Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.5

MAINTENANCE Grease Lubrication Points There are grease fittings on each lower control arm, each rear bearing carrier, on the upper control arm pivot point on the transmission and on the propshaft. Apply a maximum of 3 pumps of grease at each of these areas. Item

Recommended Lube

Method

Frequency

Polaris Premium U-Joint Grease

Grease fittings (3 pumps maximum) every 500 miles (800 km).

Grease before long periods of storage, and after pressure washing or submerging the ATV.

Front Propshaft Yoke Control Arms (front and rear) Rear Bearing Carrier Transmission Upper Pivot Point

Transmission Upper Pivot Point

Front Propshaft Yoke

Bearing Carrier

Control Arms

2.6

MAINTENANCE Maintenance quick reference III. #

Item

Engine Oil

Lube Rec.

Method

Frequency*

Polaris PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

Add oil to proper level on dipstick

Change after 1st month or first 20 hours of operation, 100 hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

Engine Coolant (400 H.O.)

Polaris 60/40 Coolant

Add coolant

Check level daily, change coolant every 2 years

Transmission

Polaris AGL Synthetic Gearcase Lubricant

Add lubricant until it is visible at the fill hole threads

Check level every 25 hours; change lubricant yearly

Front Gearcase

Polaris Premium Demand Drive Hub Fluid

Add lubricant until it is visible at the fill hole threads

Check level every 25 hours; change fluid yearly

Brake Fluid

Polaris DOT 4 Brake Fluid

Fill master cylinder reservoirs to indicated level inside each reservoir

Check level during pre-ride inspection; change fluid every 2 years

* More often under severe use, such as operated in water or under severe loads.

3. Tra

gine Oil 400 H. O. Dipstick

Drain Plug

2. Engine Coolant 4. Front

400 H.O. nder

2.7

MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants,Maintenance and Service Products Part No.

Description Engine Lubricant

2870791

Fogging Oil (12 oz. Aerosol)

2876244

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Engine Oil (Quart)

2876245

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Engine Oil (Gallon)

Gearcase / Transmission Lubricants 2877922

Premium Demand Drive PLUS Fluid (Quart)

2877923

Premium Demand Drive Hub Fluid (2.5 Gallon)

2873602

Premium AGL Synthetic Gearcase Lube (Quart) (12 count)

2873603

Premium AGL Synthetic Gearcase Lube (Gallon) (4 count)

2870465

Pump for 1 Gallon Jug Coolant

2871534

60/40 Coolant (Quart) (12 count)

2871323

60/40 Coolant (Gallon) (6 count) Grease / Specialized Lubricants

2871312

Grease Gun Kit

2871322

Premium All Season Grease (3 oz. cartridge) (24 Count)

2871423

Premium All Season Grease (14 oz. cartridge) (10 Count)

2871460

Starter Drive Grease (12 Count)

2871515

Premium U-Joint Lube (3 oz.) (24 Count)

2871551

Premium U-Joint Lube (14 oz.) (10 Count)

2871329

Dielectric Grease (Nyogelâ&#x201E;¢)

NOTE: Each item can be purchased separately at your local Polaris dealer.

2.8

MAINTENANCE Additives / Sealants / Thread Locking Agents / Misc. 2871950

Loctiteâ&#x201E;¢ Threadlock 242 (6 ml.) (12 Count)

2871326

Premium Carbon Clean (12 oz.) (12 Count)

2870652

Fuel Stabilizer (16 oz.) (12 Count)

2872189

DOT 4 Brake Fluid (12 Count)

2871557

Crankcase Sealant, 3-Bond 1215 (5oz.)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

2.9

MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE

Handlebar Component Locations

Pre-ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

voir Indicator Lights LCD

• Tires - check condition and tire pressure • Fuel and oil - fill both to their proper level; do not overfill • All brakes - check operation (includes auxiliary brake) • Throttle - check for free operation • Headlight / Taillight / Brakelight - check operation of all indicator lights and switches • Engine stop switch (key switch) - check for proper function • Wheels - check for loose wheel nuts • Air cleaner element - check for dirt or water; clean or replace • Steering - check for free operation, noting any unusual looseness in any area • Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or other fasteners • Engine coolant (if applicable) - check for proper level at the recovery bottle

Frame, Nuts, Bolts, Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

Controls Check controls for proper operation, positioning and adjustment. • Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.

2.10

Choke

Ignition Switch

MAINTENANCE FUEL SYSTEM AND AIR INTAKE

Fuel Filter

Fuel System

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel tank and carburetor.

WARNING Gasoline is extremely flammable and explosive under certain conditions. • Always stop the engine and refuel outdoors or in a well ventilated area.

Clamp fuel lines to prevent fuel leakage.

Remove line clamps at both ends of the filter.

Remove fuel lines from filter.

Install new filter onto fuel lines with arrow pointed in direction of fuel flow.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck. • If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately. • If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Fuel Filter To Carburetor

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time. 5.

Install clamps into their position on the fuel lines.

Remove line clamp tool from the fuel line.

Fuel Lines

Start engine and inspect for leaks.

Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary.

Vent Lines

Be sure fuel lines are routed properly and secured with cable ties.

• Never drain the float bowl when the engine is hot. Severe burns may result.

CAUTION Make sure lines are not kinked or pinched 3.

Check vent lines on fuel tank, crankcase, carburetor, battery and transmission for signs of wear, deterioration, damage or leakage. Replace lines every two years.

Verify vent lines are routed properly and secured with an appropriate number of cable ties.

CAUTION

Replace all fuel lines every two years. Make sure lines are not kinked or pinched

2.11

MAINTENANCE Throttle Operation

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

With engine running, turn the handlebars from full left to full right with transmission in neutral. Engine RPM should not change and the engine should not die. If either of these occur, return to the first step.

NOTE: If the throttle cable is adjusted too tight, the ETC will limit operation at low throttle positions.

Place the gear selector in neutral.

Set parking brake.

Choke (Enricher) Adjustment

Start the engine and let it idle.

Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, no adjustment is required.

Verify free play and smooth operation of choke cable. Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the desired freeplay.

Replace the throttle cable if worn, kinked, or damaged.

Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment 1.

Slide the boots off inline cable adjuster sleeve. Loosen adjuster locknut.

With handlebars centered and wheels pointing forward, turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved at the thumb lever. After making any adjustment, “flip” the lever slightly to confirm adjustment.

Choke

= In. / mm. Choke Cable Freeplay: 1/16” - 3/16” (1.6 mm - 4.76 mm) If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

Boot

Locknut

Fuel Valve Boot

Adjuster Sleeve Direction of travel

The fuel valve is used to shut off fuel flow from the fuel tank during periods of storage, vehicle transport, or during carburetor service. The fuel valve is located in-line between the tank and fuel pump.

1/16” to 1/8” Freeplay

Remove RH side panel to access.

= In. / mm. ETC/ Throttle Cable Freeplay: 1/16-1/8” (1.6-3.1 mm) 3.

Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

2.12

In-Line Fuel Valve

MAINTENANCE Carburetor Draining

Pilot Screw Location

The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.

The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

NOTE: The bowl drain screw is located on the bottom left side of the float bowl. 1.

Turn fuel valve to the “OFF” position (see “Fuel Valve” for location).

Place a clean container beneath the float bowl drain spigot or float bowl drain hose.

Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.

CAUTION The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded.

Drain Screw

Pilot Screw Location 4.

Inspect the drained fuel for water or sediment.

Tighten drain screw.

Turn fuel valve to “ON”.

Start machine and check for leaks.

Brass Plug Installed

NOTE: All tubes attached to the carburetor must be checked for pinching or blockage, as this will effect engine performance.

Brass Plug Removed

2.13

MAINTENANCE Pilot Screw and Idle Speed Adjustment

Main Air Filter Cleaning

Start engine and warm it up to operating temperature (about 10 minutes).

Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns.

It is advisable to replace the filter when it is dirty. However, in an emergency, it is permissible to clean the main filter if you observe the following practices. • Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.

NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

• If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

Air Filter / Pre-Filter Service (300)

FRONT (Engine)

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. Removal:

Pilot Screw

Remove the seat.

Release the clips from air box cover (A) and remove cover.

Pilot screws are calibrated at the factory. Each carburetor has a slightly different pilot screw setting. The specifications may require additional tuning to achieve the desired results. 3.

Connect an accurate tachometer that will read in increments of ± 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500).

Verify idle speed is correct. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to stumble and/or RPM begins to drop.

Inspect the cover seal. It should adhere tightly to the cover and seal all the way around.

Remove the air filter assembly.

Slowly turn mixture screw counter-clockwise, noting how far the mixture screw is turned out, until idle RPM begins to drop.

Cleaning: 5.

Slip the pre-filter element off of main element. Clean the pre-filter with hot soapy water.

Center the pilot screw halfway between the points noted in Step 5 and 6.

Rinse and dry thoroughly.

Inspect element for tears or damage.

Readjust idle RPM if not within specification. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Remove the breather filter. Clean the foam filter with hot soapy water, then rinse and let dry.

Engine Idle Speed (RPM) Sportsman 300 - 1400 RPM Sportsman 400 H.O. - 1375 RPM

2.14

Installation: 10. Inspect air box cover seal for damage. Replace as needed.

MAINTENANCE 11. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. 12. Reinstall air filter assembly into the air box.

Screws

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. Removal:

Remove the seat.

Release the clips from air box cover and remove cover.

Inspect the cover seal. It should adhere tightly to the cover and seal all the way around.

Loosen filter clamp and remove air filter assembly.

Foam Seal

Duct Gasket

Pre-Filter

Air Filter / Pre-Filter Service (400 H.O.)

Plugs

Cover Air Filter

Clips Seal

Air Box

Breather Filter

Clamp

Intake Boot Clamp

Sediment Tube

Cleaning:

NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. 13. Reinstall the cleaned breather filter. 14. Install air box cover and secure with clips. 15. Check the intake boot for cracks, deterioration, abrasion, or leaks. Replace as needed.

Slip the pre-filter screen off of main element. Clean the prefilter with hot soapy water.

Rinse and dry thoroughly.

Inspect pre-filter screen for tears or damage.

Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation: 9.

Inspect air box cover seal for damage. Replace as needed.

10. Reinstall pre-filter screen over main filter. Be sure the screen covers entire surface of main filter without folds, creases, or gaps. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling.

Intake Boot

2.15

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