Polaris sportsman 300 400 digital workshop repair manual 2009 2012. POLARIS SPORTSMAN 300 400 H. O. DIGITAL WORKSHOP REPAIR MANUAL 2009 2019-03-24

Polaris sportsman 300 400 digital workshop repair manual 2009 2012 Rating: 5,1/10 1503 reviews

POLARIS SPORTSMAN 400 SERVICE MANUAL Pdf Download.

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Remove cotter pin and nut from lower A-arm ball joint. While maintaining lever pressure, open bleeder screw. All pages are printable, so run off what you need and take it with you into the garage or workshop. Front Hub Nut Refer to text for procedure Pg 7. Start bearing carrier on drive shaft.

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Free POLARIS SPORTSMAN 300 400 DIGITAL WORKSHOP REPAIR MANUAL 2009

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Do not misplace the pilot mixture screw, spring, flat washer, or O-Ring. Install pilot into valve guide. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1. Look for discoloration, shiny spots, or and area that looks different than the rest of the needle. Forward Front Transmission Support Bracket 18. Install new bearing caps in yoke by hand. Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction.

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Polaris Manual

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Refer to the warning tire pressure decal applied to the vehicle. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Remove needle bearing, low gear, and inner thrust washer. Place shims on drive end of armature shaft with phenolic washer outermost on shaft. Cylinder Out of Round Limit:. Inspect pinion and output shaft bushings. Remove body panels and fuel tank as necessary to gain access to valve cover.

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POLARIS SPORTSMAN 300 400 H. O. DIGITAL WORKSHOP REPAIR MANUAL 2009

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Remove bolt securing tensioner blade to crankcase A. Remove the remaining gears and shafts as an assembly. Remove output shaft assembly, large shim, and thrust button with its small shim. Apply cutting oil to valve seat and cutter. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Seal stator wire grommet with 3 Bond 1215 or equivalent sealer.

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Free POLARIS SPORTSMAN 300 400 DIGITAL WORKSHOP REPAIR MANUAL 2009

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Keep all valves in order with their respective seat. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern. Repeat steps 1-3 to install bearing caps on outer yoke. Install and torque both lower control arm bolts. Remove cover bolts evenly in a cross pattern, and remove cover plate. Apply grease to the lip of a new input shaft seal. Seal this edge to cover on engine side 2.

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POLARIS SPORTSMAN 300 400 H. O. DIGITAL WORKSHOP REPAIR MANUAL 2009

polaris sportsman 300 400 digital workshop repair manual 2009 2012

The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve. Remove flange bolts 10 from magneto side crankcase evenly in a cross pattern. Tensioner Bolt Torque: 6 ft. Reconnect linkage rods to gear shift selector slides. Install a new lock ring and install the shaft.

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Polaris Manual

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Remove recoil housing bolts and remove housing. Clutch seals should be inspected for damage if repeated leaking occurs. Using a strap wrench on splines to hold shaft, remove front output ring gear retaining bolt, lock tab washer, and flat washer. Install the seal flush with transmission housing. Ring Gear Flat Washer Lock Plate 24. Remove armature from starter casing. Remove driven clutch retaining bolt and driven clutch.

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Polaris Manual

polaris sportsman 300 400 digital workshop repair manual 2009 2012

Excessive end play may cause engine noise at idle and slow speeds. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. Ring Piston Ring-to-Groove Clearance Feeler Gauge Top Ring Std:. Inspect bearings on output and pinion shafts. It contains detailed instructions and step by step diagrams for all workshop procedures. Inspect for broken, chipped, or worn teeth. Loosen three camshaft sprocket bolts.

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