Description: 1996 - 2013 Polaris 400, 450 & 500 Sportsman Clymer ATV Service Repair Maintenance Manual MODELS COVERED:Sportsman 400: ...2001 - 2005Sportsman 400 HO: ...2011 - 2013Sportsman 450: ...2006 - 2007Sportsman 450 Browning Edition: ...2006Sportsman 500: ...1996 - 2010Sportsman 500 RSE: ...2000 - 2002Sportsman 500 DUSE: ...2001 - 2002Sportsman 500 HO: ...2001 - 2006, ...2008 - 2013Sportsman 500 X2: ...2006 - 2010Sportsman 500 Touring: ...2008 - 2013Worker 500: ...1997 - 2001Explorer 500: ...1997 *** This manual does NOT cover 500 ATP HO models *** TABLE OF CONTENTS: CHAPTER ONE / GENERAL INFORMATIONManual organization / Warnings, cautions and notes / Safety / Serial numbers /Model identification (2004 models) / Fasteners / Shop supplies / Tools /Measuring tools / Electrical system fundamentals / Service methods / Storage / SpecificationsCHAPTER TWO / TROUBLESHOOTINGWater damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / SpecificationsCHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UPEngine oil / Oil pump priming / Oil pressure test / Transmission / Front gearcase oil / Front hub (1996-early 2004 models) / Clutch / Air filter / Fuel tank vent hose / Fuel hose and filter / Brake system / Control cables / Cooling system / Exhaust system / Suspension / Tires and wheels / Lubrication service / Fastener inspection / Valve clearance / Compression test / Spark plug / Ignition timing / Idle speed / SpecificationsCHAPTER FOUR / ENGINE TOP ENDEngine service / Engine cooling / Engine lubrication / Servicing the engine in the frame / 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 procedure / SpecificationsCHAPTER FIVE / ENGINE LOWER ENDFlywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / SpecificationsCHAPTER SIX / CARBURETOR AND FUEL SYSTEMCarburetor operation / Carburetor / Carburetor tests and adjustments / Throttle cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump / SpecificationsCHAPTER SEVEN / FUEL INJECTION SYSTEMFuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and fuel injector / Fuel pump / Fuel sender / Pressure regulator / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position sensor (TPS) / Engine coolant temperature (ECT) sensor / Electronic control module (ECM) / Self diagnosis / Throttle cable replacement / Air filter air box / SpecificationsCHAPTER EIGHT / COOLING SYSTEMAir cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / SpecificationsCHAPTER NINE / CLUTCH AND DRIVE BELTClutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / SpecificationsCHAPTER TEN / TRANSMISSION (1996-early 2004 models)Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase oil seal inspection and replacement / Shift selector linkage / SpecificationsCHAPTER ELEVEN / TRANSMISSION (LATE 2004-on MODELS)Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / SpecificationsCHAPTER TWELVE / FRONT DRIVE SYSTEMFront hub and Hilliard clutch / (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front drive axle, boots and constant velocity (CV) / joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent / control (2007-on Sportsman 500, X2 and Touring models) / SpecificationsCHAPTER THIRTEEN / ELECTRICAL SYSTEMElectrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / Alternator stator / Voltage regulator/rectifier / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (fuel injected models) / Ignition coil / Electric starting system / Starter drive gears / Starter solenoid / Headlight system / Taillight and work light / Indicator lamp (1996-2002 models) / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit (late 2004-on models) / Differential solenoid (X2 and Touring models) / Switches / Electronic throttle control (ETC) switch / All wheel drive (AWD) coil / Active descent control (ADC) coil / (2007-on X2 and Touring models) / Cooling system switch and sensor / Fuses and circuit breaker (2008 models) / Speedometer / On-board diagnostics / Winch (models so equipped) / Winch contactor (models so equipped) / SpecificationsCHAPTER FOURTEEN / FRONT SUSPENSION AND STEERINGFront wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / SpecificationsCHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVEShock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / Lower control arm (X2 and Touring models) / Upper and lower control arm inspection / Stabilizer linkage (all models except X2 and / Touring) / Stabilizer support (all models except X2 and / Touring) / Stabilizer support and bar (X2 and Touring models) / SpecificationsCHAPTER SIXTEEN / BRAKESBrake service / Front brake pad replacement / Front caliper / Output shaft brake pad replacement / (1996-1997 models) / Output shaft brake caliper (1996-1997 models) / Output shaft brake pad replacement / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / Rear brake pad replacement (2003-on models / except X2 and Touring) / Rear caliper (2003-on models except X2 and / Touring) / Rear brake pad replacement (X2 and / Touring models) / Rear caliper (X2 and Touring models) / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake bleeding tips / Brake bleeding / Brake fluid draining / Rear brake pedal / Brake disc / SpecificationsCHAPTER SEVENTEEN / BODY AND FRAMEPlastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Radiator guard (1996-2003 models) / Radiator brush guard (2004-on models) / Brush guard grill and radiator side shield / (2004-on models) / Rear rack, rail and bumper (1996-2002 models) / Rear rack and rail (2003-on except X2 and / Touring) / Rear rack and handle (Touring models) / Rear fender / Rear quarter panel (X2 models) / Footwell / Footwell support bracket (X2 and Touring models) / Rear storage box (all models except X2 and Touring) / Cargo box (X2 models) / Specifications SPECIFICATIONS: Publisher: Clymer Publishing / Haynes Manuals Inc. Softcover: 715 pages Dimensions: 8.5 x 11.0 x 2.0 inches Part number: M3655 ISBN-13: 9781599696393
Price: 41.95 USD
Location: Midland, Michigan
End Time: 2024-08-06T18:45:48.000Z
Shipping Cost: 0 USD
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Return shipping will be paid by: Buyer
Returns Accepted: Returns Accepted
Item must be returned within: 30 Days
Refund will be given as: Money Back
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Compatible Model: Explorer 500, Worker 500, Sportsman 500 Touring, Sportsman 500 X2, Sportsman 500 HO, Sportsman 500 DUSE, Sportsman 500 RSE, Sportsman 500, Sportsman 450 Browning Edition, Sportsman 450, Sportsman 400 HO, Sportsman 400
Compatible Make: Polaris
Machine Type: ATV
Country/Region of Manufacture: Malaysia
Material: Paper
Part #:: M3655
Compatible Year: 2013, 2012, 2011, 2010, 2009, 2008, 2007, 2006, 2005, 2004, 2003, 2002, 2001, 2000, 1999, 1998, 1997, 1996
Manufacturer Part Number: M3655
Brand: Clymer
Surface Finish: Glossy
