2005 POLARIS SPORTSMAN 400 MANUAL PDF

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Make sure the diaphragm is pliable but not swollen. Install airbox assembly and transmission vent line. A gritty feeling indicates contamination. Re- fer to bushing replacement in this chapter.

Engine Installation Notes 4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. Slide prop shaft back sportsma away from front housing. Page 13 – projex inbox. Apply 3Bondt to mating surface of transmission case. Thermostat Installation, Oil Pipes – projex inbox. Remove three Phillips screws at back of headlight pod.

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Remove caliper mounting bolts and lift caliper off of disc.

Remove flange bolts 10 from magneto side crankcase evenly in a cross pattern. The recoil starter, starter motor, starter drive, flywheel, stator, cam chain and sprockets can be serv- iced with the engine in the frame. Apply clean engine oil to all ring surfaces and ring lands.

The sediment tube will require more frequent ser- vice if the vehicle is operated in wet conditions or at high throttle openings for extended sportsmab. The plunger should move smoothly in and out of the tensioner body.

Install the seal flush with transmission housing. Check the oil pump and oil 205 mating surfaces to be sure they are clean and not damaged.

Moveable Sheave Bushing Inspection – projex inbox. Make sure the cylinder mounting bolt holes are clean and free of debris.

Polaris Sportsman 400 Service Manual

Outwardly, both drive and driven clutch resemble those used in a standard Sporttsman system, however, there are some important differences in the EBS clutches: Check brake system for fluid leaks. Tire Pressure, Tire Inspection – projex inbox. Inspect electrodes for wear and carbon buildup.

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Starter Assembly – projex inbox.

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See photo at right. When the fan switch reaches the specified temperature, it be- comes conductive and sends power to the fan motor. DH Brake Caliper Torque 18 ft. Use a feeler gauge to measure the connecting rod big end side clearance. Check bearing condition, and snap ring location. Screw and Washer Assembly 4. The cooling system is under pressure and serious burns may result. Run engine two to three minutes until warm.

Pvt Sealing And Ducting Components – projex inbox. Carburetor Inspection – projex inbox.

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