Polaris 400, 450 and 500 Sportsman 1996 - 2008 (Clymer M365-3)

This Clymer ATV repair manual provides detailed maintenance, troubleshooting and repair information for selected Polaris Sportsman, Worker and Xplorer ATV models. Written specifically for the do-it-yourself enthusiast, it covers everything from routine servicing and fault diagnosis through to major repairs and complete overhaul procedures.

The manual also includes colour wiring diagrams and covers EFI-equipped models within the listed model range.

Includes:

• Polaris Sportsman 400 (2001–2005)
• Polaris Sportsman 400 HO (2011–2013)
• Polaris Sportsman 450 (2006–2007)
• Polaris Sportsman 450 Browning Edition (2006)
• Polaris Sportsman 500 (1996–2010)
• Polaris Sportsman 500 RSE (2000–2002)
• Polaris Sportsman 500 DUSE (2001–2002)
• Polaris Sportsman 500 HO (2001–2006 and 2008–2013)
• Polaris Sportsman 500 X2 (2006–2010)
• Polaris Sportsman Touring 500 (2008–2013)
• Polaris Worker 500 (1997–2001)
• Polaris Xplorer 500 (1997)
• EFI-equipped models within the listed coverage
• Colour wiring diagrams

Excludes:

• Polaris 500 ATP HO models

Manual Contents: Quick Reference Data Chapter 1 – General Information

• Manual organisation
• Warnings, cautions and notes
• Safety information
• Serial numbers and model identification
• Fasteners and shop supplies
• Tools and measuring equipment
• Electrical system fundamentals
• Service methods
• Storage
• Specifications

Chapter 2 – Troubleshooting

• Water damage
• Engine starting and performance problems
• Electronic Throttle Control (ETC)
• Fuel system
• Engine and lubrication system
• Cylinder leakdown testing
• Clutch system
• Gearshift linkage and transmission
• Electrical testing and troubleshooting
• Meter assembly
• Front gearcase and final drive
• Front suspension and steering
• Brake system
• Specifications

Chapter 3 – Lubrication, Maintenance and Tune-Up

• Engine oil and filter servicing
• Oil pressure testing
• Transmission and front gearcase oil servicing
• Front hub oil servicing on applicable models
• Clutch and drive belt inspection
• Air filter and fuel system servicing
• Brake system maintenance
• Throttle and choke cable adjustment
• Cooling system inspection
• Suspension, tyres and wheel alignment
• Lubrication points
• Valve clearance
• Compression testing
• Spark plugs and ignition timing
• Idle speed
• Specifications

Chapter 4 – Engine Top End

• Engine servicing
• Cooling and lubrication systems
• In-frame servicing
• 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 procedures
• Specifications

Chapter 5 – Engine Lower End

• Flywheel and stator plate
• Recoil starter
• Crankcase
• Oil pump
• Oil system one-way check valve
• Break-in procedures
• Specifications

Chapter 6 – Carburettor and Fuel System

• Carburettor operation, testing and adjustment
• Throttle cable replacement
• Choke cable
• Fuel tank
• Fuel shutoff valve
• Fuel level sender
• Air filter and air box
• Fuel pump
• Specifications

Chapter 7 – Fuel Injection System

• Fuel system initialisation
• Fuel system depressurisation
• Fuel line fittings
• Throttle body
• Fuel rail and injector
• Fuel pump and sender
• Pressure regulator
• Fuel tank
• Engine management sensors
• Electronic Control Module (ECM)
• Self-diagnosis
• Throttle cable replacement
• Air filter and air box
• Specifications

Chapter 8 – Cooling System

• Air and liquid cooling systems
• Hoses and clamps
• Radiator
• Cooling fan
• Coolant pump
• Thermostat
• Specifications

Chapter 9 – Clutch and Drive Belt

• Clutch system operation
• Clutch tools
• Clutch drying
• Drive belt
• Belt alignment
• Drive clutch
• Driven clutch
• Specifications

Chapter 10 – Transmission: 1996 to Early 2004 Models

• Transmission servicing and inspection
• Shift shafts
• Front output shaft
• Gearcase oil seals
• Shift selector linkage
• Specifications

Chapter 11 – Transmission: Late 2004-On Models

• Transmission servicing
• Transmission shafts
• Differential gear assembly
• X2 and Touring model components
• Snorkel shaft
• Shift selector linkage
• Specifications

Chapter 12 – Front Drive System

• Front hub and Hilliard clutch
• Front hubs on later, X2 and Touring models
• Front drive axles
• CV joints and boots
• Front drive shaft
• Front gearcase
• Active Descent Control on applicable models
• Specifications

Chapter 13 – Electrical System

• Electrical system fundamentals
• Battery and charging system
• Alternator and voltage regulation
• Ignition systems
• Electric starting system
• Lighting systems
• Sensors and switches
• All-Wheel Drive systems
• Active Descent Control
• Cooling system switches and sensors
• Fuses and circuit breakers
• Speedometer
• On-board diagnostics
• Winch systems on equipped models
• Specifications

Chapter 14 – Front Suspension and Steering

• Front wheel
• Front strut, cartridge and spring
• Control arm
• Handlebar
• Tie rods
• Steering post
• Tyres and wheels
• Specifications

Chapter 15 – Rear Suspension and Final Drive

• Shock absorber
• Rear hub and bearing carrier
• Rear drive axle
• CV joints and boots
• Upper and lower control arms
• X2 and Touring suspension components
• Stabiliser linkage and supports
• Specifications

Chapter 16 – Brakes

• Brake servicing
• Front brake pads and calipers
• Output shaft brake systems
• Rear brake pads and calipers
• Front and rear master cylinders
• Brake hose replacement
• Brake bleeding
• Brake fluid draining
• Rear brake pedal
• Brake discs
• Specifications

Chapter 17 – Body and Frame

• Seat and side panels
• Front and rear fenders
• Front racks, rails and storage boxes
• Front bumper
• Radiator and brush guards
• Rear racks and rails
• Rear quarter panels
• Footwells and support brackets
• Rear storage boxes
• Cargo box on X2 models
• Specifications

Additional Contents:

• Index
• Colour wiring diagrams