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Screw and Washer Assembly 4.

Owner’s Manuals | Polaris

Remove dipstick and fill tank with 2 quarts 1. Make sure hole in oil deflector is clear and unobstructed.

Inspect pinion and output shaft bushings. Position the piston support block PN A beneath the mznual skirt to support the piston during cylinder installation.

Continue to screw front housing in, making sure O-ring enters housing without damage. Place gear selector in neutral.

Polaris Sportsman 400 Manuals

Measure free length of spring with a Vernier caliper. This is accomplished through weights and a spring inside the unit which react to the centrifugal force applied to the clutch from the engine RPM.


The plunger should move smoothly in and out of the tensioner body. Awd Front Housing Removal – projex inbox. Always inspect camshaft lobe if rocker arms are worn or damaged. Crankshaft Straightening – projex inbox.

Master Cylinder Installation Sealing Washers 15 ft. Remove cover bolts evenly spottsman a cross pattern, and remove cover plate. Screw and Washer Assembly 5. Inspect cylinder for wear, scratches, or damage.

Tap cover with soft face Remove all bolts hammer to remove. Piston Installation – projex inbox. Replace the cam- shaft as an assembly if the actuator ball is worn or dam- aged. Inspect PVT inner cover-to engine pokaris. It is important that the same number and thickness of washers are reinstalled beneath the spider during as- sembly.

Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing. Front Gearcase Lubrication S Be sure vehicle is level before proceeding. Polaaris Sportsman Manuals. Apply Polaris Premium Starter Drive grease to the camshaft main journals and cam lobes.


Support caliper so as not to kink or bend brake line. Combustion Chamber – projex inbox. Remove front support bracket. Steering Post Assembly, Decal Replacement – projex inbox. Install flywheel puller PN and remove flywheel. Refer to illustration on following page for fuel pump compo- nent identification.

Polaris Sportsman Manual | eBay

Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. Remove the inner PVT cover. Smooth idle generally indicates good compression. Polaris industries all-terrain vehicle owner’s manual pages. Piston Removal – projex inbox.

Keep all parts in order with respect to their location in the cylinder head.