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Periodic inspection and main- tenance is required to keep the system operating at peak performance.

Remove rear hub and bearing carrier. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Place tensioner cam on front spacer and tensioner shoe on rear spacer.

Also See for Sportsman Owner’s manual – lolaris Use and care manual – 40 pages. Pump Shaft Oil Seal Installation – projex inbox.

Polaris Sportsman Manual | eBay

Make sure surface of access plate and transmission are clean and free of oil and grease. Recommended Lubricants and 4400. Publication Numbers, Paint Codes – projex inbox. Some fasteners and procedures will vary. This manual will save Rear Wheel Nuts 20 Ft.


Install flywheel puller PN and remove flywheel. Drive Belt Installation – projex inbox. Using a hammer and drift punch, remove the seal sleeve by driving it off evenly being careful not to nick or damage the sleeve mounting area Polaria. One Way Valve Installation – projex inbox.

Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. The Teflon bushings are self-lubricating.

Owner’s Manuals | Polaris

Use electrical contact cleaner to clean starter motor parts. Review all information below before proceeding.

Transmission Disassembly – projex inbox. To install a new spring: Remove the check plug. Place main adapter Item 8 on puller. Fuel Pump Assembly 2. Wear eye protection or a face shield during cylinder head disassembly and reassembly.

Polaris Sportsman 400 Manuals

Install sportsma in holding fixture and loosen the spider counterclockwise using spider removal tool. Remove cam chain drive sprocket B and Woodruff key from crankshaft. Camshaft Removal – projex inbox.


Don’t have an account? A digital multitester must be used for this test. Keep all valves in order with their respective seat.

Polaris Sportsman 400 Service Manual

Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover. Make sure the O-ring is fully seated. Pvt Disassembly – projex inbox.

Seal stator wire grommet with 3 Bond or equivalent sealer. Remove bolt securing tensioner blade to crankcase A.