Polaris A12MH46AX Service manual

Page 1
1
GENERAL
MAINTENANCE
ENGINE
FUEL SYSTEMS
BODY / SUSPENSION
2
3
4
5
Page 2
6
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
7
8
9
10
Page 3
NOTES
Page 4
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN)1.2
ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 SPORTSMAN 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 SPORTSMAN 500 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2012 SPORTSMAN TOURING 500 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2012 SPORTSMAN FOREST TRACTOR 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
1
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
1.1
Page 5
GENERAL INFORMATION
A12 MN 50 AX
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Descriptor
Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No
Individual Serial Number
* This could be either
a number or a letter
Powertrain
Emissions
4 X A M N 5 0 A * 0 P 0 0 0 0 0 0
A
B
C
MODEL NUMBER INFORMATION
The machine model number must be used with any correspondence regarding warranty or service.
Vehicle Identification Number (VIN)
Model Number
Engine Designation Numbers
EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke,
Electric Start 
EH46PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start
Vehicle and Engine Serial Numbers
The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number (A) whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow.
The vehicle serial number is located:
400 / 500 Non Touring Vehicles (B)
500 Touring Vehicles (C)
1.2
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 6
Transmission I.D. Location
The Transmission I.D. number is located
on the RH side transmission case; viewable
from the RH side of the vehicle.
Publication Part Numbers
GENERAL INFORMATION
1
Year Model Model No.
2012
2012
2012 Sportsman 400 H.O. A12MH46AX, AZ 9923420 9923421 2012 Sportsman 500 H.O. A12MH50AD, AQ, AX, AZ, 9923420 9923422
2012
2012
Sportsman Touring 500
H.O.
Sportsman Touring 500
H.O.
International
Sportsman Forest 500
International
Sportsman Forest Tractor
500 EFI International
Owner's
Manual PN
A12DH50AX, AZ 9923410 9923411
A12DH50FX 9923438 9923413
A12MH50FF 9923423 9923424
A12MN50ET 9923430 9923431
Parts
Manual PN
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
1.3
Page 7
GENERAL INFORMATION
VEHICLE SPECIFICATIONS
2012 Sportsman 400 H.O.
MODEL NUMBER: A12MH46AX, AZ, AF
ENGINE MODEL: EH460PLE050
Category Dimension
Length 83 in. / 210.8 cm Width 48 in. / 121.9 cm Height 48 in. / 121.9 cm Wheel Base 50.75 in. / 128.9 cm Ground Clearance 11.25 in. / 28.6 cm Dry Weight 688 lbs. / 312 kg Front Rack Capacity 90 lbs. / 41 kg Rear Rack Capacity 180 lbs. / 81.6 kg Towing Capacity 1225 lbs. / 555.7 kg Max. Weight Capacity 485 lbs. / 220 kg Hitch Tongue Weight 120 lbs. / 34 kg Unbraked Trailer Towing
Capacity (EU)
Data based on EU Directive: 76/432/EEC
1786 lbs. / 810 kg
Engine
Platform Fuji 4-cycle, L/C, Single Cyl. Engine Model Number EH460PLE050 Engine Displacement 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio 10.1:1 Compression Pressure 50-90 psi Engine Idle Speed 1200+/- 200 RPM Engine Max Speed 7000 RPM Cooling System / Cap. Liquid / 2.7 qt. (2.5 L) Overheat Warning HOT on Instrument Cluster Lubrication Dry Sump Oil Requirements PS-4 Plus / 2 qt. (1.9 L) Exhaust System Single Pipe - USFS Approved
Carburetion Carburetor model Mikuni BST 34mm Main Jet 160 Pilot Jet / Pilot Air Jet 42.5 / 160 Jet Needle 4IB33-3 Needle Jet P-6M Pilot / Air Screw 2.75 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump (Impulse) Fuel Capacity / 4.25 gal. (16 L) Fuel Requirement
(Octane)
Alternator Output 260 watt @ 3000 RPM Voltage Regulator 3-Phase PDM Pod Lighting 1x 12V / 50 Watts Grill Lighting 2x 12v / 50 Watts Brake Light 12V / 26.9 watts Tail Light 12V / 8.26 watts Ignition System DC / CDI Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E / .035 in. (.9 mm) Battery Maintenance-Free / 12 Amp Hr.
Circuit Breakers
Starting Electric
Instrument Cluster
87 Octane (minimum)
89 Oxygenated
Electrical
10A - Accessory / 10A - Fan /
15A - Main Harness
Digital Gauge LCD, Analog
Speedometer
1.4
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 8
GENERAL INFORMATION
Drivetrain
Transmission Type In-Line H/L/N/R/P Transmission Fluid Type
/ Fluid Capacity Front Gearcase Fluid Type
/ Fluid Capacity Gear Ratio :
Low (Front/Rear) Rev (Front/Rear) High (Front/Rear)
Clutch Type CVT Belt 3211077
Steering / Suspension Front Suspension / Shock MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock IRS / Progressive Rate Rear Travel 9.5. / 24.1 cm Turning Radius 65 in. / 165.1 cm (unloaded) Shock Preload Adjustment
Front / Rear Toe Out 0-1/16 in. (0-.159 mm)
Wheels / Brakes
Front Wheel Size Front Tire Model / Size
Rear Wheel Size Rear Tire Model / Size
Tire Air Pressure - F / R 5 psi (34.5 kPa)
Brakes - Front & Rear
Brake Fluid Polaris DOT 4 Brake Fluid
AGL Plus 33.8 oz.
(1000 ml)
Polaris Demand Drive Hub
Fluid / 8.97 oz / 265 ml
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
Front -Non Adjustable.
Rear - Ratchet Style- Std.
12x5
NHS 489 / 25 x 8-12
12x8
NHS 489 / 25 x 10-12
Single Control Hydraulic Disc
JETTING CHART
ALTITUDE
0-1800
Meters
(Feet)
(0-6000)
1800-3700
(6000-
12000)
Table 1-1: Clutching (NON EBS)
Altitude
M e t e r s
(Feet)
0-1800
(0-6000)
1800-3700
(6000-
12000)
AMBIENT TEMPERATURE
Below 40° F
Below 5° C
167.5 160
155 150
Shift
Weight
10WHF
5632283
20-40 or
10RH
5631356
(20-40)
5630709
(10RH)
Above +40° F
Above +5° C
Drive Clutch Spring
Blue / Grey
7042202
1
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
1.5
Page 9
GENERAL INFORMATION
2012 Sportsman 500 H.O.
MODEL NUMBER: A12MH50AX, AZ, AD, AQ, FF, FY, FX
ENGINE MODEL: EH500PLE13B
Category Dimension / Capacity Length 83 in./210.8 cm Width 48 in./121.9 cm Height 48 in./121.9 cm Wheel Base 50.75 in./128.9 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 696 lbs./313 k g
(Wet weight model FF, FY,
FX)
776 lbs / 352 kg) Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Max. Weight Capacity 485 lbs. / 220 kg Towing Capacity 1225 lbs ./ 555.7 kg Unbraked Trailer Towing
Capacity (EU)*
NOTE: *Data based on EU Directive: 76/432/EEC
Hitch Tongue Capacity
1786 lbs. / 810 kg
120 lbs./54.4 kg
Rear rack capacity and
tongue weight not to
exceed 180 lbs./82 kg
ENGINE
Platform Fuji Single Cylinder Engine Model Number EH500PLE13B Engine Displacement 498cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression
Release Engine Idle Speed Engine Max Operating Rpm 7000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 litre Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre Exhaust System Single Pipe USFS Approved
Fuel System
Carburetor Mikuni BST 40mm Main Jet 150 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 1 Turn Out (initial) Pilot Air Jet 40 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 15.5 liters
Electrical
Alternator Output 260 w @ 3000 RPM Voltage Regulator 3-phase PDM Lights : Pod 50 watts Grill 2 x 50 watts Brake 26.9 watts Tail 8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery Maintenance-Free / 12 Amp
Circuit Protection 5 / 15 / 20 Amp Fuses
Starting Electric Instrument Cluster Analog Speedo w/ LCD
1200+/- 200 RPM
87 Octane (minimum)
or 89 Oxygenated
Hr.
10 Amp Circuit Breaker - Fan
1.6
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 10
Table 1-2: Sportsman 500 H.O.
GENERAL INFORMATION
Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz.
(1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio :
Low (Front/Rear) Rev (Front/Rear) High (Front/Rear)
Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen-
Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment
Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe O u t 0-1/16 in / .0 - .159 mm Wheels / Brakes
Front Wheel Size Front Tire Model / Size
Rear Wheel Size Rear Tire Model / Size
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
dent - w/ 2" Coil-over
shock
Front -Non Adjustable.
Rear - Ratchet Style- Std.
12x5
NHS 489 / 25 x 8-12
12x8
NHS 489 / 25 x 10-12
Tire Air Pressure - F / R 5 psi (34.5 kPa)
Brakes - Front & Rear
Brake Fluid
Single Control Hydraulic Disc
Polaris DOT 4 Brake
Fluid
Table 1-4: Clutching (EBS and NON EBS)
Meter
s
(Feet)
Altitude
0-1800
(0-6000)
1800-
3700
(6000-
12000)
Shift
Weight
10 WHF
(5632283)
10 RH
(5630709)
Drive Clutch
Spring
Green / Blue
(7041157)
Green / Blue
(7041157)
1
Table 1-3: Sportsman 500 H.O. Jetting
AMBIENT TEMPERATURE
M e t e r s
(Feet)
Altitude
0-1800
(0-6000)
1800-3700
(6000-
12000)
Below 40 ° F
Below 5 ° C
155 150
147.5 142.5
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
+40 to +80 ° F
+5 to +28 ° C
© Copyright 2011 Polaris Sales Inc.
1.7
Page 11
GENERAL INFORMATION
2012 Sportsman Touring 500 HO
MODEL NUMBER: A12DH50AX, AZ
 
ENGINE MODEL: EH500PLE13B
Category Dimension / Capacity Length 86 in./218 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 723 lbs./328 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./82 kg Max. Weight Capacity 485 lbs. / 220 kg Towing Capacity 1225 lbs. / 555.7 kg Unbraked Trailer Towing
Capacity (EU)*
NOTE: *Data based on EU Directive: 76/432/EEC
Hitch Tongue Capacity 120 lbs./54.4 kg
1995 lbs. / 905 kg
Rear rack capacity and
tongue weight not to
exceed 180 lbs./82 kg
ENGINE
Platform Fuji Single Cylinder Engine Model Number EH500PLE13B Engine Displacement 498cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression
Release Engine Idle Speed 1200+/- 200 RPM Engine Max Operating Rpm 7000 RPM Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre Exhaust System Single Pipe USFS Approved
Fuel System
Carburetor Mikuni BST 40mm Main Jet 150 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 2 Turns Out (initial) Pilot Air Jet 160 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 16 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 260 w @ 3000 RPM Lights : Pod 50 watts Grill 2 x 50 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 1 BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery Maintenance-Free / 12 Amp
Hr.
Circuit Breakers 5 / 15 / 20 Amp Fuses
10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD
1.8
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 12
Table 1-5: Sportsman Touring 500 H.O.
GENERAL INFORMATION
Drivetrain
Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz.
(1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio :
Low (Front/Rear) Rev (Front/Rear) High (Front/Rear)
Clutch Type PVT EBS Belt 3 211113
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen-
Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment
Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe O u t 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Front Wheel Size Front Tire Model / Size
Rear Wheel Size Rear Tire Model / Size
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
dent - w/ 2" Coil-over
shock
Front -Non Adjustable.
Rear - Ratchet Style- Std.
12x5
NHS 489 / 25 x 8-12
12x8
NHS 489 / 25 x 11-12
Tire Air Pressure - F / R 5 psi (34.5 kPa)
Brakes - Front & Rear
Brake Fluid
Single Control Hydraulic Disc
Polaris DOT 4 Brake
Fluid
Table 1-7: Sportsman 500 H.O. Clutching
Altitude Shift Weight
0-1800
Meters
(Feet)
(0-6000)
1800-3700
(6000-
12000)
10 WHF
(5632283)
10 RH
(5630709
Drive Clutch
Spring
Green / Blue
(7041157)
Green / Blue
(7041157)
1
Table 1-6: Sportsman 500 H.O. Jetting
AMBIENT TEMPERATURE
Meters
(Feet)
Altitude
0-1800
(0-6000)
1800-3700
(6000-
12000)
Below 40 ° F
Below 5 ° C
155 150
147.5 142.5
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
+40 to +80 ° F
+5 to +28 ° C
© Copyright 2011 Polaris Sales Inc.
1.9
Page 13
GENERAL INFORMATION
2012 Sportsman Forest Tractor 500 EFI Specifications MODEL NUMBER: A12MN50ET, EX
ENGINE MODEL: EH500PLE216
Category Dimension / Capacity Length 83 in./210.8 cm Width 48 in./121.9 cm Height 48 in./121.9 cm Wheel Base 50.75 in./128.9 cm Ground Clearance 11.25 in./28.6 cm WET Weight 807 lbs. / 366 kg Front Rack/Box Capacity 85 lbs./39 kg Rear Rack Capacity 180 lbs./81.6 kg Max. Weight Capacity 485 lbs. / 220 kg Towing Capacity (rear) 1225 lbs ./ 555.7 kg Towing Capacity (front) 850 lbs. / 386 kg Unbraked Trailer Towing
Capacity (EU)* Hitch Tongue Capacity 120 lbs./54.4 kg
NOTE: *Data based on EU Directive: 76/432/EEC
1786 lbs. / 810 kg
Rear rack capacity and
tongue weight not to
exceed 180 lbs./82 kg
ENGINE
Platform Fuji 4 stroke, Single Cylin-
der Engine Model Number EH500PLE216 Engine Displacement 498cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure Compression Release 50-
90 psi Engine Idle Speed 1150 ± 50 RPM Max Engine Speed 7000 RPM Cooling System / Capacity Liquid / 2.7 qts (2.5 L) Overheat Warning HOT on Instrument Clus-
ter Lubrication Pressurized Dry Sump Oil Requirements / Capac-
ity Exhaust System Single Pipe Fuel System Carburetor model Electronic Fuel Injection
Fuel Pump (in tank assem­bly)
Fuel Filters 30 micron in-tank Fuel Injector Visteon EFI Controller Visteon Fuel Capacity / Require-
ment
Electrical Alternator Output 350 watt @ 5000 RPM Voltage Regulator 3-phase Lights : High Beam 50 watts Low Beam 37 watts Brake 26.9 watts Tail 8.26 watts Parking Lights 5 watts x 2 Turn 10 watts Ignition System DC/CDI Ignition
Polaris 0W-40 / 2 qts
(1.9L)
(EFI)
25 Liters per hour at 39 psi
4.12 gal. (15.6 L) 87 (minimum)
89 Oxygenated
1.10
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 14
GENERAL INFORMATION
ENGINE
Ignition Timing 10°± 1° BTDC @ Idle RPM Spark plug / Gap NGK BKR6E
.035 in. / .9 mm
Battery / Amp Hr Lead Acid - 30 Amp Hr Circuit Breakers Fan 20 Amp
Harness 20 Amp
Fuel Pump-ECU 15 Amp
Instrument Cluster-Voltage
Regulator 6 Amp Starting Electric Instrument Cluster LCD Gauge / Pod Indicator
lights
Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz.
(1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio :
Low (Front/Rear) Rev (Front/Rear) High (Front/Rear)
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1 Clutch Type PVT EBS Belt 3211113 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen-
dent - w/ 2" Coil-over
shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment
Front / Rear
Front -Non Adjustable.
Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes
Front Wheel Size Front Tire Model / Size
Rear Wheel Size Rear Tire Model / Size
12x6 Cast Alloy
Kenda BCLAW
25 x 8 - 12
12x8 Cast Alloy
Kenda BCLAW
25 x 12.5 - 12
Tire Air Pressure - F / R 5 psi (34.5 kPa)
Brakes - Front & Rear
Single Control Hydraulic Disc
Brake Fluid Polaris DOT 4 Brake Fluid
1
A12MN50ET Clutching
Altitude
0-1800
Meters
(Feet)
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
(0-6000)
1800-3700
(6000-
12000)
Shift
Weight
10 WHF
(5632283)
10 RH
(5630709
Drive Clutch
Spring
Green / Blue
(7041157)
Green / Blue
(7041157)
1.11
Page 15
GENERAL INFORMATION
MISC. NUMBERS/CHARTS
Conversion Table
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
(3.14)xR
2
x H (height) = Cylinder Volume
°C to °F: 9 (°C + 40) ¸ 5 - 40 = °F °F to °C: 5 (°F + 40) ¸ 9 - 40 = °C
1.12
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 16
Standard Bolt Torque Specification
Grade 2
Grade 5
Grade 8
GENERAL INFORMATION
1
Bolt Size
1/4-20 5 (7) 8 (11) 12 (16) 1/4-28 6 (8) 10 (14) 14 (19) 5/16-18 11 (15) 17 (23) 25 (35) 5/16-24 12 (16) 19 (26) 29 (40) 3/8-16 20 (27) 30 (40) 45 (62) 3/8-24 23 (32) 35 (48) 50 (69) 7/16-14 30 (40) 50 (69) 70 (97) 7/16-20 35 (48) 55 (76) 80 (110) 1/2-13 50 (69) 75 (104) 110 (152) 1/2-20 55 (76) 90 (124) 120 (166)
Grade 2
Ft. Lbs. (Nm)
Grade 5
Ft. Lbs. (Nm)
Grade 8
Ft. Lbs. (Nm)
Metric Bolt Torque Specification
Grade
Bolt Size
M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2) M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5) M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10) M6 3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18) M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45) M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85) M12 26 (35) 33 (45) 63 (85) 97 (130) 11 (150) M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240) M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)
4.6 4.8 8.8 / 8.9 10.9 12.9
Ft. Lbs. (Nm) Dry Threads
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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Page 17
GENERAL INFORMATION
SAE Tap Drill Sizes
Thread Size/ Drill Size Thread Size / Drill Size
#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64
Metric Tap Drill Sizes
Tap Size Drill Size
3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32
Decimal Equivalent
Nearest Fraction
Decimal Equivalents
1/64 . . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
3/64 . . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . . . .0625
5/64 . . . . . . . . . . . . . . . . . .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
7/64 . . . . . . . . . . . . . . . . . .1094. . . 3 mm =.1181"
1/8 . . . . . . . .1250
9/64 . . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
11/64 . . . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
13/64 . . . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . . . .2344. . . 6 mm = .2362"
1/4 . . . . . . . .25
17/64 . . . . . . . . . . . . . . . . . .2656. . . 7 mm = .2756"
9/32 . . . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 . . . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
23/64 . . . . . . . . . . . . . . . . . .3594
3/8 . . . . . . . .375
25/64 . . . . . . . . . . . . . . . . . .3906. . . 10 mm = .3937"
13/32 . . . . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . . . .4219. . . 11 mm =.4331"
7/16 . . . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
31/64 . . . . . . . . . . . . . . . . . .4844
1/2 . . . . . . . .5. . . . . . . . . . . . 13mm = .5118"
33/64 . . . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . . . .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . . . .5781. . . 15 mm = .5906"
19/32 . . . . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . . . .6094
5/8 . . . . . . . .625. . . . . . . . . . 16mm=. 6299"
41/64 . . . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
43/64 . . . . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . . . .6875
45/64 . . . . . . . . . . . . . . . . . .7031. . . 18 mm = .7087"
23/32 . . . . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . . . .7344. . . 19 mm = .7480"
3/4 . . . . . . . .75
49/64 . . . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 . . . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
53/64 . . . . . . . . . . . . . . . . . .8281
27/32 . . . . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . . . .8594. . . 22 mm = .8661"
7/8 . . . . . . . .875
57/64 . . . . . . . . . . . . . . . . . .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
61/64 . . . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
63/64 . . . . . . . . . . . . . . . . . .9844
1. . . . . . . . . 1.0
1.14
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 18
GENERAL INFORMATION
Key Cover PN 5433534
Paint Codes
PAINTE D PA R T
Sportsman Frame Black 9440 P-067
COLOR
DESCRIPTION
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required.
Series # Part Number
20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278
DITZLER
NUMBER
POLARIS
NUMBER
1
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
1.15
© Copyright 2011 Polaris Sales Inc.
Page 19
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center. ACV: Alternating current voltage. ADC: Active Descent Control. Alternator: Electrical generator producing voltage
alternating current.
ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft
and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage. Electrical Open: Open circuit. An electrical circuit which
isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet. Ft. lb. / Foot Pound: A force of one pound at the end of
a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a
lever one meter in length, applied in a rotational direction.
l or ltr: Liter. Left Side: Always referred to based on normal operating
position of the driver.
m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved
through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm
= approximately .040,.
Nm: Newton meters. OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current
flow.
oz.: Ounce/ounces. PDM: Power Distribution Module. Piston Clearance: Total distance between piston and
cylinder wall.
psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery
charging system output at approx. 14.5 DCV as engine RPM increases. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat. Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually
there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance;
4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt : The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.
1.16
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Page 20
MAINTENANCE
CHAPTER 2
MAINTENANCE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.7
LUBRICATION / FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
LUBRICATION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
ADC SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ADC SYSTEM FLUID RESERVOIR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE. . . . . . . . . . . . . . . . . . . 2.11
VEHICLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
SHIFT LINK ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT . . . . . . . 2.13
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
CHOKE (ENRICHER) ADJUSTMENT - (500 CARB) . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
RADIATOR/GRILL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
RADIATOR COOLANT LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
BREATHER FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2
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2.1
Page 21
MAINTENANCE
AUXILIARY BRAKE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SUSPENSION SPRING
PRELOAD ADJUSTMENT2.29
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEEL, HUB, AND SPINDLE
TORQUE TABLE2.30
WHEEL REMOVAL FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
CARBURETOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
CHOKE (ENRICHER) ADJUSTMENT (NON EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
IDLE SPEED ADJUSTMENT (NON EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
FUEL FILTER (NON EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
SPECIAL TOOLS
SPX Corporation - 1-800-328-6657 or http://polaris.spx.com
2.2
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MAINTENANCE
WARN IN G
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil imme­diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
2
E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
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MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
(KM)
 Steering - Pre-Ride -
Front-suspension - Pre-Ride -
Rear-suspension - Pre-Ride -
Tires - Pre-Ride -
ADC fluid level
(if equipped) Brake fluid level - Pre-Ride -
Brake lever travel - Pre-Ride -
Brake systems - Pre-Ride ­Wheels /fasteners - Pre-Ride ­Frame fasteners - Pre-Ride -
Engine oil level - Pre-Ride -
E
Passenger Seat Lock Out - Pre-Ride - Verify Seat is secured
Air filter, pre-filter - Daily - Inspect; clean often
E
Air box sediment tube - Daily - Drain deposits when visible
E
Coolant - Daily -
Headlamp/tail lamp - Daily -
Air filter,
main element
E
Recoil housing - Weekly -
Brake pad wear 10 H Monthly 60 (100) Inspect periodically
Battery 20 H Monthly 125 (200) Check terminals; clean; test Front gearcase oil 25 H Monthly 155 (250) Inspect level; change yearly*
Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly
- Pre-Ride -
Make adjustments as needed.
Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing
- Weekly - Inspect; replace as needed
Drain water as needed, check often if operating in wet conditions (If equipped)
Remarks
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.
2.4
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Periodic Maintenance Chart
MAINTENANCE
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
(KM)
Engine breather
filter (if equipped)
E
Engine oil change
(break-in)
E
General
lubrication Shift Linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust
Steering 50 H 6 M 310 (500) Lubricate
Front suspension 50 H 6 M 310 (500) Lubricate
Rear suspension 50 H 6 M 310 (500) Lubricate
EThrottle Cable/ETC
Switch Air intake ducts/
E
flange Drive belt 50 H 6 M 310 (500) Inspect; adjust; replace as needed Cooling system
Engine oil change
E
Oil filter change 100 H 6 M 620 (1000) Replace with oil change
E
Oil tank vent hose 100 H 12 M 620 (1000) Inspect routing, condition
E
Valve clearance 100 H 12 M 620 (1000) Inspect; adjust
E
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
25 H Monthly 155 (250) Inspect; replace if necessary
25 H 1 M 155 (250)
50 H 3 M 310 (500)
50 H 6 M 310 (500)
50 H 6 M 310 (500)
50 H 6 M 310 (500)
100 H 6 M 620 (1000)
Perform a break-in oil change at one month Lubricate all grease fittings, pivots, cables, etc.
Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks
Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at 25 hours/one month
Remarks
Have an authorized Polaris dealer perform these services.
2
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MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
(Km)
Fuel system 100 H 12M
E
Fuel Filter 100 H 12M
E
Radiator 100 H 12M
Cooling hoses 100 H 12M
Engine mounts 100 H 12M
Exhaust muffler / pipe
Spark plug 100 H 12M
E
Ignition Timing 100 H 12M
E
Wiring 100 H 12M
Clutches (drive
and driven) Front wheel
bearings
Brake fluid 200 H 24M
Spark arrestor 300 H 36M
Toe adjustment - Inspect periodically; adjust when parts are replaced
Auxiliary brake - Inspect daily; adjust as needed
Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)
100 H 12M
100 H 12M
100 H 12M
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
620
(1000)
1000
(1600)
1240
(2000)
1860
(3000)
Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years
Replace yearly
Inspect; clean external surfaces
Inspect for leaks
Inspect
Inspect
Inspect; replace as needed
Inspect
Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
Inspect; clean; replace worn parts
Inspect; replace as needed
Change every two years
Clean out
Remarks
Have an authorized Polaris dealer perform these services.
2.6
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MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244
2876245
2878068
2878069
2878070
2876160
PS-4 Plus Synthetic 4-Cycle Engine Oil (Quart)
PS-4 Plus Synthetic 4-Cycle Engine Oil (Gallon)
Gearcase / Transmission Lubricants
AGL Plus Gearcase Lubricant (1 Qt.) (12 Count)
AGL Plus Gearcase Lubricant (1 Gal.) (4 Count)
AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count)
ATV Angle Drive Fluid (8 oz.) (12 Count)
NOTE: Each item can be purchased separately at your local Polaris dealer.
Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
2871950
2871326
2870652 Fuel Stabilizer (16 oz.) (12 count) 2872189 DOT 4 Brake Fluid (12 count) 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
Loctite Threadlock 242 (6 ml.) (12 count)
Premium Carbon Clean (12 oz.) (12 count)
LUBRICATION / FLUIDS
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
2
2872276
2877922
2877923
2870465 Oil Pump for 1 Gallon Jug
2871312 Grease Gun Kit
2871322
2871423
2871460 Starter Drive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871329 Dielectric Grease (Nyogel™)
2871323 60/40 Coolant (Gallon) (6 Count)
ATV Angle Drive Fluid (2.5 Gal) (2 Count)
Demand Drive Plus (Quart)
Demand Drive Plus (2.5 Gallon)
Grease / Specialized Lubricants
Premium All Season Grease (3 oz. cartridge) (24 Count)
Premium All Season Grease (14 oz. cartridge) (10 Count)
Coolant
• Tires - check tire condition and air pressures
• Fuel and oil - fill both to their proper level; Do not overfill
• All brakes - check operation and adjustment (includes auxiliary brake)
• Throttle -check for free operation
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins
• Air cleaner element - check for dirt or water; clean or replace
• Steering - check for free operation, noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery bottle
2871534 60/40 Coolant (Quart) (12 Count)
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Page 27
MAINTENANCE
2
3A
3B
4
5
6
7
1
Lubrication Components
# ITEM LUBE METHOD
Change after 1st month, 6 months, or 100
1. Engine Oil Polaris PS-4 Plus
Polaris AGL Plus
2. Transmission
Front
3
Gearcase Demand Drive PLUS
4. Brake Fluid
5. Front A-Arm
6. Rear A-Arm
7. Propshafts
* Perform more often under severe use, such as operation in water and under severe loads. (A) Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more
often under severe conditions (i.e. operating in water or hauling heavy loads).
Synthetic Gearcase
Lube
Polaris DOT 4 Brake
Fluid
Polaris All Season
Grease
Polaris All Season
Grease
Polaris U-Joint Grease
(C)
Check oil tank dipstick and
add to proper level.
Add lube to bottom fill hole. Change annually (B)
Drain as directed.
Add specified quantity.
Fill master cylinder reservoir
to indicated level
Locate fitting and grease. Semi-annually (A)
Locate fitting and grease Semi-annually (A)
Locate fitting and grease. Semi-annually (A)
hours thereafter; Change more often (25­50 hours) in extremely dirty conditions, or
short trip cold weather operation.
Gearcase - Change annually (B)
As required, change fluid every 2 years
FREQUENCY*
(B) Annually or 100 hours of operation Refer to Maintenance Schedule for additional information. Service more often
under severe conditions (i.e. operating in water or hauling heavy loads). ADC gearcase fluid should be changed every 25hrs of operation in extreme use conditions (i.e. continuous operation on hilly or mountainous terrain or if ADC ‘on’ is primary mode of AWD operation).
(C) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special.
2.8
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MAINTENANCE
=
= T
Drain Plug
Left Side View
Fill Plug
Front Gearcase
Fill -Demand
Hub Fluid
Drive PLUS
Front Gearcase Lubrication
The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding and in PARK
• Check vent hose to be sure it is routed properly and unobstructed
• The correct front gearcase lubricant to use is Polaris Demand Drive PLUS Hub Fluid.
To Change Gearcase Lubricant:
2
1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.
2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque to specification.
Specified Lubricant:
Demand Drive PLUS Hub Fluid
Gearcase Capacity: 8.97oz. (265 ml.)
Fill Plug Torque: 8-10 ft.lbs. (11-14 Nm)
Drain Plug Torque: 11 ft.lbs. (15 Nm)
To Check the Lubricant Level:
The front gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.
3. Remove fill plug. Inspect the O-ring.
4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).
5. Install / torque fill plug and check for leaks.
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2.9
Page 29
MAINTENANCE
= T
CHECK / FILL PLUG
= T
=
= T
DRAIN PLUG
Transmission Lubrication
The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.
• Be sure vehicle is level and in Park before proceeding.
• Check vent hose to be sure it is routed properly and unobstructed.
• Follow instructions to check/change transmission lubricant.
To Change Lubricant:
1. Remove transmission drain plug to drain the oil. Discard used oil properly.
NOTE: The check/fill plug is a 3/16” hex.
2. Clean and reinstall the drain plug. Torque to specification.
Transmission Check/Fill Plug Torque:
14 ft.lbs. (19 Nm)
To Check the Fluid Level:
1. Remove check / fill plug from the left side of transmission and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole threads.
NOTE: The check/fill plug is a 5/16” hex.
Transmission Drain Plug Torque:
14 ft.lbs. (19 Nm)
3. Remove fill plug.
4. Add the correct amount of Polaris AGL Plus Gearcase Lubricant.
Transmission - Specified Lubricant:
Polaris AGL Plus Gearcase Lubricant
(Gallon - PN 2878069) (1qt. - PN 2878068)
Capacity: 33.8 oz. (1000 ml)
5. Check for leaks.
6. Install fill plug. Torque to specification.
Transmission Check/Fill Plug Torque:
14 ft.lbs. (19 Nm)
2.10
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MAINTENANCE
ADC Reservoir
= T
ADC SYSTEM (IF EQUIPPED)
ADC System Fluid Reservoir Location
The Active Descent Control reservoir is located by the radiator fill cap under the storage box access panel. Check the level and verify it is between the MAX and MIN lines, Add only Polaris ADC fluid when required.
ADC Differential Hydraulic Circuit Fluid Change
NOTE: If empty reservoir is encountered, filling of fluid is still possible. Verify air is not trapped before proceeding with step 7.
8. Continue steps 6-8 on both sides in sequence until clean fluid is seen when bleeding occurs.
9. Re-torque both bleeder valves to specification and reinstall cover caps.
Bleeder Valve Torque:
80 in. lbs. (9 Nm)
10. Fill reservoir with to a level midway between ‘MAX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir oil.
11. Replace reservoir cap securely and wipe clean any residue.
2
1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit.
2. Thoroughly clean area around and on remote reservoir and bleeder valves.
3. Remove reservoir cap and diaphragm assembly.
4. Make sure hydraulic oil inside reservoir is free of debris. If any debris is found, use clean rag or suction device to remove from the reservoir.
NOTE: Debris in reservoir may block porting and produce inadequate bleeding of the system. Decreased performance may be encountered with inadequate bleed of the hydraulic circuit.
5. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Polaris Demand Drive PLUS hydraulic fluid.
6. Locate bleeder valves found on either side of differential and remove the protective caps.
7. Turn bleeder valves counter-clockwise to loosen. Loosen bleeder screw slowly, allowing oil and any trapped air to flow out of fitting.
IMPORTANT: Do not allow hydraulic fluid in reservoir to drain below minimum fill line. Close bleeder valve before oil level falls below minimum fill line. Refilling empty reservoir will result in air pockets becoming trapped.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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MAINTENANCE
Shift Mount
Shifter
Shift Link Rod
ETC Cover
Removal Sequence
III. 1
1
2
3
4
5
6
VEHICLE INSPECTION
Shift Link Rod Inspection
NOTE: Shift rod is preset at time of manufacturer.
1. Lubricate pivot points with a light aerosol lubricant or grease if desired.
Throttle Inspection
Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.
1. Place the gear selector in Park.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. Adjust cable tension as needed until lock-to-lock turning can be accomplished with no rise in engine rpm.
5. Replace the throttle cable if worn, kinked, or damaged.
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.
2. Twist screwdriver slightly while lifting on the cover to release snap.
3. Repeat procedure at the other five locations as shown.
NOTE: Do not attempt to remove cover until all latch points are released.
2.12
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MAINTENANCE
= In. / mm.
Boot
Adjuster Sleeve
Lock Nut
Boot
Direction of Travel
1/16-1/8” Freeplay
WARN IN G
Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
1. Slide boot off throttle cable adjuster and jam nut.
2. Place shift selector in neutral and set parking brake.
3. Loosen lock nut on in-line cable adjuster (Ill. 1).
4. Turn adjuster until specified freeplay is achieved at thumb lever. (see illustration). After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.
Fuel System
* Gasoline is extremely flammable and explosive
under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before d is a ss e mb ly . * Never drain the fuel system when the engine is h o t . S e v e r e b u r n s m a y r e s u l t * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel. * Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. * Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. * If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention i mm ed i at el y. * If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clot hi ng. * Always stop the engine and refuel outdoors or in a well ventilated area.Keep away from open flames and electrical components when removing fuel filter.
2
Throttle Freeplay:
.0625 - .1250" (1.58 - 3.17mm)
5. Tighten lock nut securely and slide boot completely in place to ensure a water-resistant seal.
6. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
• Always stop the engine and refuel outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately.
• If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.
Never drain the system when the engine is hot.
Severe burns may result.
2.13
Page 33
MAINTENANCE
CAU T ION
CAU T ION
= In. / mm.
A
A
A
Fuel Lines
1. Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly, the connectors latched and the lines secured with cable ties.
Make sure lines are not kinked or pinched
3. Replace all fuel lines every two years.
NOTE: See Chapter 4 for fuel line routing diagram.
Vent Lines
Check fuel tank, oil tank, crankcase, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.
Be sure vent lines are routed properly and secured with cable ties.
Compression Test
NOTE: 500 and 455 4-Stroke engines are equipped with
an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 60-90 psi during a compression test.
Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine condition on models with automatic decompression. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage testers as crankshaft seals may dislodge and leak).
Cylinder Compression
Standard 60-90 PSI
Cylinder Leakage
Make sure lines are not kinked or pinched
Choke (Enricher) Adjustment - (500 Carb)
Verify free-play and smooth operation of the choke cable. Adjustments to the choke can be made by turning the cable adjustment in or out to gain the desired cable free­play.
(Inspect for cause if leakage exceeds 10%)
Service Limit: 10%
Engine Mounts
Inspect rubber engine mounts (A) for cracks or damage. Check engine fasteners and ensure they are tight.
Choke Cable Freeplay: 1/16 - 3/16" (1.6 - 4.76mm)
2.14
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MAINTENANCE
CAU T I ON
= T
Spark Plug Gap SPORTSMAN 400 and 500
.035” (0.9 mm)
WARN IN G
Spark Plug
1. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed.
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.
4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.
5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.
Battery Maintenance
Complete battery servicing information for both conventional and sealed batteries can be found in
Chapter 10 of this manual.
2
CALIFORNIA PROPOSITION 65 WARNING: Batteries, battery posts, terminals and related
accessories contain lead and lead compounds and
other chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with
skin, eyes or clothing.
ANTIDOTE:
External: Flush with water.
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call a physician immediately.
6. If necessary, replace spark plug with proper type.
Severe engine damage may occur if the incorrect
spark plug is used.
7. Apply a small amount of anti-seize compound to the spark plug threads.
8. Install spark plug and torque to specification.
Recommended Spark Plug:
BKR6E
Spark Plug Torque: 14 Ft. Lbs. (19 Nm)
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE: Expected battery shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.
New Batteries: before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/ hour capacity (i.e. 12amp hr x .10 = 1.2 amp charg­ing). Do not use the alternator to charge a new bat­tery.
Batteries must be fully charged
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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MAINTENANCE
Antifreeze Hydrometer
CAU T I ON
Liquid Cooling System Overview
The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.
Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period.
Overheating of engine could occur if air is not fully purged from system.
Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
Coolant Strength / Type
Test the strength of the coolant using an antifreeze hydrometer.
Cooling System Hoses
• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.
• Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.
• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.
Polaris 60/40 Anti-Freeze/ Coolant
(PN 2871323)
2.16
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1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.
2. Check tightness of all hose clamps.
Do not over-tighten hose clamps at radiator,
or radiator fitting may distort,
causing a restriction to coolant flow.
Radiator hose clamp torque is 36 in. lbs. (4 Nm).
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MAINTENANCE
Recovery Bottle
Radiator/Grill Screen
1. Check radiator air passages for restrictions or damage. Check and clean the radiator grille if needed.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low pressure water.
Cooling System Pressure Test
System Pressure Test
1. Remove radiator cap cover located under the storage box access panel. See Chapter 5.
2. Remove recovery bottle hose from coolant filler.
3. Connect a Mity Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.
Coolant Level Inspection
The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.
2
With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If not:
1. Remove reservoir cap. Inner splash cap vent hole must be clear and open.
2. Fill reservoir to upper mark with Polaris Premium 60/ 40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
3. Reinstall cap.
NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.
Radiator Cap Pressure Test
1. Remove radiator cap and test using a cap tester (commercially available).
2. The radiator cap relief pressure is 13 lbs (89.6 kpa).
RECOMMENDED COOLANT
Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.
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MAINTENANCE
WARN IN G
Radiator Coolant Level
Never remove the radiator pressure cap when the
engine is warm or hot. Escaping steam and fluid
can cause severe burns. The engine must be
allowed to cool before removing the pressure cap.
NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected via the radiator cap first and coolant added if necessary.
NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.
To Access the Radiator Pressure Cap:
1. Open the front rack storage area.
2. Remove the (4) T-25 screws securing the access cover to the front cab as shown below.
3. Move the seal out of the sealing channel and pull up on the front of the access cover. Remove the access cover.
4. The pressure cap is now accessible.
2.18
5. Remove the pressure cap and inspect fluid level. Using a funnel, add coolant until the fluid level is to the top of the filler neck.
6. Reinstall the pressure cap and install the front access cover.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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MAINTENANCE
A
Gasket
Carb Boot
Main Element
Pre-Filter
Cover
Filter Clamp
Front
Main Filter
Filter Support
Air Box
Proper Filter Placement
Air Filter/Pre-Filter Service
It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.
The pre filter should be inspected before each ride, and if required, cleaned using the following procedure:
1. Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs.
NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.
3. Remove (6) clips (A) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.
Installation:
9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.
10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.
2
NOTE: Apply a small amount of general purpose grease
to the sealing edges of the filter before reinstalling.
4. Loosen clamp and remove air filter assembly.
Cleaning:
5. Slip the pre-filter element off of main element. Clean the pre filter with hot, soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.
NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.
11. Install air box cover and secure with the (6) clips.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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MAINTENANCE
Sediment Tube
Drain Plug
Recoil Drain
B
Air Box Sediment Tube
Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube.
1. Remove drain plug from end of sediment tube.
2. Drain tube.
3. Reinstall drain plug.
NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.
Breather Hose
1. Be sure breather line is routed properly and secured in place. CAUTION: Make sure lines are not kinked or pinched.
NOTE: In-line breather filter service life is extended when the foam air box pre-filter is in place and maintained properly. Never operate the engine without the pre-filter.
Recoil Housing
• Drain the housing periodically to remove
moisture.(If Equipped)
Breather Filter Inspection
Four-cycle ATV engines are equipped with a breather filter. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side of the engine.
In-line breather filters can be installed in either direction.
• Drain the recoil housing after operating the ATV in
very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10 mm wrench. Reinstall screw once housing has been drained.
CAUTION: Make sure the manual start handle (B)
is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.
• Water will enter the recoil housing if the starter
handle (B) is disengaged from the rope guide when under water.
• After travelling in wet areas the recoil housing and
starter should always be drained completely by removing the recoil.
• Do not open the crankcase drain unless the
engine has ingested water. Some engine oil will be lost if crankcase drain is opened.
• If recoil handle (B) seal has been damaged, the
handle should be replaced.
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Page 40
MAINTENANCE
A
ADD 8 OZ.
NORMAL
FULL
Maintain Oil Level In Normal range
Screw Dipstick in completely to check
WARN IN G
A
B
C
D
E
Reference mark
C
Engine Oil Level
The oil tank is located on the left side of the vehicle. To check the oil level:
1. Set machine on a level surface.
2. Clean the area around the dip stick.
3. Start and run engine for 20-30 seconds. This will return oil to its true level in the oil tank.
4. Stop engine, remove dipstick (A) and wipe dry with a clean cloth.
5. Reinstall dipstick, screw the dipstick into place.
NOTE: The dipstick must be screwed completely in to ensure accurate measurement.
6. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top line and the bottom line on the dipstick. Add oil as indicated by the level on the dipstick. Do not overfill.
Oil and Filter Change
Oil Filter Torque:
Turn by hand until filter gasket
contacts sealing surface, then
turn an additional 1/2 turn
Oil Filter Wrench:
(PV-43527)
Oil Tank Screen Fitting Torque:
25 ft-lb (34Nm)
Recommended Engine Oil:
Polaris PS 4 PLUS
Synthetic, 2W-5o
Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.
NOTICE: Care must be taken to ensure that the fluids are contained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly of any component containing fluids.
1. Place vehicle on a level surface.
2. Clean area around drain plug (A) at bottom of oil tank.
3. Run engine two to three minutes until the engine is warm.
4. After two or three minutes stop the engine.
5. Place a drain pan beneath oil tank and remove the drain plug (A). CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.
2
NOTE: Rising oil level between checks in cool weather
driving, can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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6. Allow oil to drain completely.
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MAINTENANCE
= T
CAU T ION
Oil Filter
Engine Sump
Engine Sump Drain Plug- Bottom View
Drain
7. Replace sealing washer (B) on drain plug (A).
NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.
8. Reinstall the drain plug (A) and torque it to specification.
Oil Tank Drain Plug Torque:
14 ft. lbs. (19 Nm)
Crankcase Drain Plug Torque:
14 ft. lbs. (19 Nm)
9. Loosen clamp (D).
10. Remove oil hose (E) from screen fitting (C) on bottom of oil tank.
11. Remove screen fitting (C) and clean the screen.
12. Apply Loctite™ thread sealant 505 or an equivalent pipe thread sealant or PTFE sealant tape to clean, oil free threads of fitting (C).
13. Install screen fitting (C) and rotate a minimum of 2 1/ 2 turns (clockwise) into the tank threads. Then rotate the screen fitting clockwise until the nipple of the screen fitting aligns with the reference marking on the tank.
15. Place shop towels beneath oil filter. Use Oil Filter Wrench (PV-43527), turn filter counterclockwise to remove.
16. Using a clean dry cloth, clean filter sealing surface on the crankcase.
17. Lubricate the o-ring on new filter with a thin film of engine oil. Check to make sure the O-ring is in good condition.
18. Install the new filter and turn it by hand until the filter gasket contacts the sealing surface, then turn an additional 1/2 of a turn.
19. Approximately 1 cup of engine oil will remain in the crankcase. To drain, remove drain plug found on lower right side of crankcase.
Maximum torque for the screen fitting
is 25 ft-lb (34Nm), do not over tighten.
NOTE: Maximum torque for the screen fitting is 25 ft-lb (34Nm), do not over tighten.
14. Install oil hose (E) on fitting (C) and re-install clamp (D).
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9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or scratches.
20. Reinstall drain plug and torque to specification.
21. Remove dipstick and fill tank with 2 quarts (1.9 L) of Polaris Premium 4 Synthetic Oil.
22. Place gear selector in Park and set parking brake.
NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown in the Oil Pump Priming Procedure.
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MAINTENANCE
Slit
(A)
(A) Vent Hose to Air Box
Oil Lines To E n gi n e
CAU T ION
Sprocket alignment pin facing up
Crankshaft-to-Camshaft Centerline
23. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.
24. Dispose of used filter and oil properly.
Oil Pump Priming Procedure
NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.
1. Clamp or pinch off vent line (A) approximately 2” from oil tank to avoid the end of oil tank vent fitting, and the vent line’s pressure relief slit
Valve Clearance
Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke.
1. Remove the seat.
2. Remove body panels and fuel tank as necessary to gain access to valve cover.
3. Remove the spark plug high tension lead and remove the spark plug. CAUTION: Place a clean shop towel into the spark plug cavity to prevent dirt from entering.
4. Remove rocker cover bolts, cover and gasket.
NOTE: It may be necessary to tap cover lightly with a soft-faced hammer to loosen it from the cylinder head.
5. Remove timing inspection plug from recoil housing.
Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustment.
2
2. Run engine at IDLE for 10-15 seconds.
3. Remove the vent line clamp. The oil pump will now be properly primed and ready for field operation. Note: If
the system is primed properly you should hear some air release. If you do not, the system has not primed. Repeat the process if necessary.
6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close.
NOTE: At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward, directly in line with the crankshaft to camshaft center line as shown. The camshaft lobes should be pointing downward.
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MAINTENANCE
Feeler gauge for both valves
WARN IN G
7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves.
Intake Valve Clearance Adjustment
1. Insert a .006" (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw.
2. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.
3. Hold adjuster screw and tighten adjuster lock nut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.
6. Repeat this step for the other intake valve.
INTAKE VALVE CLEARANCE
.006” (.15 mm)
Exhaust Valve Clearance Adjustment
1. Insert a .006" (.15mm) feeler gauge between end of both exhaust valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/ Clutch Adjuster Tool (PA-44689) can be used to adjust the engines valves.
NOTE: Both feeler gauges should remain inserted during adjustment of each valve.
EXHAUST VALVE CLEARANCE
.006” (.15 mm)
3. When clearance is correct, hold adjuster screws and tighten locknuts securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.
Steering
The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.
NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.
NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.
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Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized
MSD-certified technician when replacing worn or
damaged steering parts.
Use only genuine Polaris replacement parts.
Page 44
MAINTENANCE
Check for Loose Wheel or Hub
= In. / mm.
III. 1
Chalk Line Measurement “A”
Measurement “B”
Tie Rod End/Steering Inspection
• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.
• Repeat inspection for inner tie rod end on steering post.
• Replace any worn steering components. Steering should move freely through entire range of travel without binding.
• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.
Camber and Caster
The camber and caster are non-adjustable.
Wheel Alignment
1. Place machine on a smooth level surface.
2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm center section can be used as an indicator of whether the handlebars are straight. The center section should always point straight back from the steering post.
3. Place a chalk mark on the center line of the front tires approximately 10" (25.4 cm) from the floor or as close to the hub/axle center line as possible. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.
4. Measure the distance between the marks and record the measurement. Call this measurement “A”.
5. Rotate the tires 180o by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle centerline.
6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8" to 1/4" (.3 to.6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8" to 1/4" (.3 to .6 cm) wider than the measurement at the rear (B)
2
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause ( possible loose wheel nuts or loose front hub components).
• Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures.
Wheel Toe-Out:
(A) - (B) = 0 to 1/16" (0 to 1.6mm)
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MAINTENANCE
CAU T ION
= T
Hold Rod End
Correctly Tightened Jam Nut
Incorrectly Tightened Jam Nut
III. 2
WARN IN G
III. 1
Clean Out Plug
Toe Alignment Adjustment
If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.
During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts. If the rod end is positioned incorrectly it will not pivot, and may break
Exhaust Pipe
• Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components.
• To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.
• Never run the engine in an enclosed area.Exhaust contains poisonous carbon monoxide gas.
• Do not go under the machine while it is inclined.Set the hand brake and block the wheels to prevent roll back.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified.
IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. See illustration 2.
• After alignment is complete, torque jam nuts to specification.
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
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2.26
Failure to heed these warnings could result in serious personal injury or death.
The exhaust pipe must be periodically purged of accumulated carbon as follows:
1. Remove the clean out plugs located on the bottom of the muffler.
2. Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.
© Copyright 2011 Polaris Sales Inc.
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MAINTENANCE
1 ft.
Sight Glass
Parking Lock Brake
3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.
4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING
Brake System Inspection
The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.
2
• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.
• Use Polaris DOT 4 Brake Fluid
• Use Polaris DOT 4 Brake Fluid
6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
• Check brake for excessive travel or spongy feel.
• Check brake system for fluid leaks.
• Check friction pads for wear, damage or looseness.
• Check surface condition of the disc.
2.27
Page 47
MAINTENANCE
= In. / mm.
Minimum
Thickness
.180” / 4.6 mm,
Auxiliary Brake
Full Height
Full Engagement
Floor Board Surface
Auxiliary Foot Brake Pedal
Brake Pad Inspection
Pads should be changed when the friction material is worn to .180” / 4.6 mm, or about the thickness of a dime.
Brake Pad Service Limit:
.180" (4.6 mm)
Hose/Fitting Inspection
Auxiliary Brake Testing
The auxiliary brake should be checked for proper function.
1. Support the rear wheels off the ground.
2. While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest.
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.Tighten any loose fittings and replace any worn or damaged parts.
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Page 48
MAINTENANCE
= In. / mm.
1” or greater
1/8, to 1/4, Free Play
Floorboard
50 lbs
Center Spring Adjustment Ring
1
2
Inspect Boots
Auxiliary Brake Adjustment (Hydraulic)
Use the following procedure to inspect the hydraulic auxiliary (foot) brake system and adjust or bleed if necessary:
First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.
If less than one inch, two things must be examined:
Free Play:
Suspension Spring Preload Adjustment
2
Shock Spanner Wrench
(PN 2871095)
Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary, using the spanner wrench (2) to turn the adjustment cam (1).
Front Suspension
Foot Brake Freeplay:
1/8 - 1/4" (3.2 - 6.35 mm)
If free play is excessive, inspect pedal, linkage, and master cylinder for wear or damage and replace any parts as needed.
Bleeding:
If free play is correct and brake pedal travel is still excessive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9.
Compress and release front suspension. Damping should be smooth throughout the range of travel.
Check all front suspension components for wear or damage.
Inspect front strut cartridges for leakage.
CV Shaft Boot Inspection
Inspect the CV shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement.
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MAINTENANCE
Throttle assembly clamp
Align clamp edge with knurl
WARN IN G
Controls
Check controls for proper operation, positioning and adjustment.
Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.
Wheels
Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.
Operating an ATV with worn tires will increase the
possibility of the vehicle skidding and possible loss
of control.
Worn tires can cause an accident.
Always replace tires when the tread depth
measures 1/8” (.3 cm) or less.
Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.
Wheel, Hub, And Spindle Torque Table
Align throttle control assembly clamp with knurl on handlebar.
Item Specification
Steel - Front Wheel Nuts 27 Ft. Lbs. (37 Nm) Steel - Rear Wheel Nuts 27 Ft. Lbs. (37Nm)
Aluminum
Front Wheel Nuts
Aluminum
Rear Wheel Nuts
Front Hub Retaining Nut 60 ft.lbs. (81 Nm)
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm)
30 ft. lbs. + 1/4 Turn
(41 Nm + 1/4 Turn)
30 ft. lbs. + 1/4 Turn
(41 Nm + 1/4 Turn)
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MAINTENANCE
Front & Rear Wheels
Front & Rear
Wheel Nuts (4)
See table Below
Front Hub Nut 60 ft. lbs. (81 Nm)
Rear Hub Nut 80 ft. lbs. (109 Nm)
CAU T ION
CAU T ION
Steel Wheel Aluminium Wheel
Wheel Removal Front or Rear
1. Stop the engine, place the transmission in Park and lock the parking brake.
2. Loosen the wheel nuts slightly.
• Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.
3. Remove the wheel nuts and remove the wheel.
Wheel Installation
1. With the transmission in Park and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
2. Attach the wheel nuts and finger tighten them.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper torque listed in the table.
2
If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel.
Tire Pressure
Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle.
Tire Pressure (Cold)
Front Rear
5 (34.5 Kpa) 5 (34.5Kpa)
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MAINTENANCE
WARN IN G
Tread
Depth 1/8” (3 mm)
CAU T ION
Boot
Tire Inspection
• Improper tire inflation may affect ATV maneuverability.
• When replacing a tire always use original equipment size and type.
• The use of non-standard size or type tires may affect ATV handling.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
CARBURETOR MAINTENANCE
Choke (Enricher) Adjustment (Non EFI)
If the choke knob does not stay out when pulled, adjust the choke tension by tightening (clockwise) the jam nut under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled.
Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident. 
Always replace tires when the tread depth measures 1/8” (.3 cm) or less.
Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.
Pilot Screw
The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/ air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.
The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tamper­ing. Removal of the tamper proof plug is not permit­ted. For service purposes, cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded.
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Pilot Screw Adjustment
Pilot Screw Location
Brass Plug Installed
Brass Plug Removed
Pilot Screw
FRONT
(Engine)
MAINTENANCE
2
1. Start engine and warm it up to operating temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.
Pilot screws are calibrated at the factory. Each
carburetor has a slightly different pilot screw
setting. The specifications below are the “base”
recommended setting, and may require
additional tuning to achieve the desired results.
_______________________
Pilot Screw Adjustment:
Sp ortsman 500 - 2 T urn s Out
Sportsman 400 - 2.75 Turns Out
3. Connect an accurate tachometer that will read in increments of + or - 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN
8712500).
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MAINTENANCE
CV Carburetor
Idle Screw
Arrow Indicates Direction of Flow
To Carburetor
4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.
7. Center the pilot screw between the points in Step 5 and 6.
8. Re adjust idle speed if not within specification.
Idle Speed Adjustment (Non EFI)
Fuel Filter (Non EFI)
The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter.
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to Ill. at right).
NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
Idle speed:
1100 +/- 200 RPM
1. Shut off fuel supply at fuel valve.
2. Remove seat and locate filter on right side of atv. NOTE: Remove side panel if necessary.
3. Remove line clamps at both ends of the filter.
4. Remove fuel lines from filter.
5. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.
6. Install clamps on fuel line.
7. Turn fuel valve “ON”.
8. Start engine and inspect for leaks.
2.34
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Carburetor Draining
Drain Screw
Drain tube attached here
Fuel Valve
The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.
NOTE: The bowl drain screw is located on the bottom left side of the float bowl.
1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot or bowl drain hose.
3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.
NOTE: All tubes attached to the carburetor must be check for pinching or blockage, as this will effect engine performance
MAINTENANCE
2
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MAINTENANCE
Maintenance Schedule
Service Date Hours / Miles Service Performed Serviced By:
2.36
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ENGINE
CHAPTER 3
ENGINE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
SPORTSMAN 500 H.O. ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4
SPORTSMAN 500 H.O. ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SPORTSMAN 400 H.O. ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
SPORTSMAN 400 H.O. ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.12
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
CRANKSHAFT STRAIGHTENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
OIL FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CAM CHAIN TENSIONER / ROCKER ARM /CAMSHAFT REMOVAL . . . . . . . . . . . . .3.18
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
ROCKER ARM / SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
AUTOMATIC COMPRESSION RELEASE REMOVAL / INSPECTION . . . . . . . . . . . . .3.21
AUTOMATIC COMPRESSION RELEASE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 3.21
CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
CYLINDER HEAD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
CYLINDER / PISTON REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . .3.30
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.32
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
PISTON IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
STARTER DRIVE REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
3
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ENGINE
FLYWHEEL AND STATOR REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAM CHAIN / TENSIONER BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
ONE WAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
OIL PUMP REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
COUNTER BALANCER SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.40
CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CRANKCASE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
OIL SEAL / MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED) . . . . . 3.42
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
END PLAY INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
COUNTER BALANCER SHAFT END PLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 3.44
OIL PUMP SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
PUMP SHAFT OIL SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CRANKSHAFT / COUNTER BALANCE / OIL PUMP INSTALLATION . . . . . . . . . . . . . 3.45
CRANKCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE INSTALLED) . . . . . . . . . . 3.47
ONE WAY VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
CAM CHAIN DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
CAM CHAIN / CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
CAMSHAFT TIMING ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
CAM CHAIN TENSIONER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . 3.54
ROCKER SHAFT / ROCKER ARM ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . 3.55
THERMOSTAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
OIL PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
RECOIL (ACCESSORY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
3.2
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ENGINE
2
4
5
6
1
6 mm
Cylinder Head
1
2
5
7
8
9
Crankcase
3
Cylinder Base Pattern
6
10
Pattern
3
4
SPECIFICATIONS
Torque Specifications
TORQUE SPECIFICATIONS
Fastener Size
Blind Plug (Oil Pressure)
Camshaft Sprocket 6mm 5-6.5 (7-9 Nm) Camshaft Chain
Tensioner Lever Camshaft Chain
Te ns i on er Camshaft Chain
Tensioner Cap Throttle Body Adaptor 8mm 12-14 (16-20 Nm) Crankcase 8mm 14-15 (19-21 Nm) Crankshaft Slotted Nut
(Cam Chain Drive Sprocket)
Cylinder Base Bolts
Cylinder Head Bolts
Drive Clutch Bolt 7/16 - 20 40 (55 Nm) Flywheel 16mm 58-72 (78-98 Nm) Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Oil Drain Bolt
(Crankcase) Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm) Hard Metal Oil Line
Banjo Fitting
Oil Hose Fitting
Oil Pump 6mm 5-6.5 (7-9 Nm) Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm) One Way Valve 11 mm 14-19 (20-25 Nm) Recoil Housing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Support 8mm 8-10 (11-13 Nm) Rocker Adjuster Screw 6mm 6-7 (8-10 Nm) Water Pump Impeller
Nut
1/8 PT
(28tpi)
6mm 5-6.5 (7-9 Nm)
6mm 5-6.5 (7-9 Nm)
11mm 6.5 (9 Nm)
28mm 35-51 (47-69 Nm)
10mm
6mm
11mm
6mm
14mm 14-17 (19-23 Nm)
N/A 11-16 (15-21 Nm)
1/8 Pipe
Thread
6mm 5-6.5 (7-9 Nm)
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
ft. lbs. (Nm)
6.5-11 (9-15 Nm)
45-49 (61-67 Nm)
6-8 (9-11 Nm)
Refer to Engine
Assembly for torque
procedure
6.5-11 (9-15 Nm)
© Copyright 2011 Polaris Sales Inc.
Water Pump Housing Cover
Stator Plate 6mm 5-6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor -- 26 ± 2.1 (35 ± 3 Nm)
6mm 5-6.5 (7-9 Nm)
Engine Fastener Torque Patterns
Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below.
3.3
3
Page 59
ENGINE
Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
Cylinder Head / Valve EH50PLE (498cc)
Rocker arm ID .8669-.8678”(22.020-22.041 mm)
Rocker Arm
Camshaft
Cylinder Head
Valve Seat Contacting width
Valve G u ide
Val ve Margin thickness
Valve
Valve Spring
Rocker shaft OD .8656-.8661 (21.987-22.0 mm)
Rocker shaft Oil Clearance
In
Cam lobe height
Ex
Camshaft journal OD
Camshaft journal bore ID
Camshaft Oil clearance
Surface warpage limit .0020” (.05 mm) Standard height 3.870” (98.3 mm)
In
Ex
Inner Diameter .2362-.2367" (6.0-6.012 mm) Protrusion above head .689-.709" (17.5-18.0 mm)
In
Ex
Stem diameter In .2343-.2348" (5.950-5.965 mm)
Stem Oil clearance
Overall length
Overall length
Squareness Inner
Std
Limit .0059" (.15 mm)
Std .0008-.0021” (.020-.054 mm) Limit .0039” (.10 mm) Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Mag 1.4935-1.4941" (37.935-37.950 mm) PTO 1.4935-1.4941" (37.935-37.950 mm) Mag 1.4963-1.4970" (38.005-38.025 mm) PTO 1.4963-1.4970" (38.005-38.025 mm) Std .0022-.0035" (.055-.090 mm) Limit .0039" (.10 mm)
Std .028" (.7 mm) Limit .055" (1.4 mm) Std .039" (1.0 mm) Limit .071" (1.8 mm)
Std .039" (1.0 mm) Limit .031" (.8 mm) Std .047" (1.2 mm) Limit .031" (.8 mm)
Ex .2341-.2346" (5.945-5.960 mm) In .0014-.0024" (.035-.062 mm) Ex .0016-.0026" (.040-.067 mm)
In 3.976" (101.0 mm) Ex 3.984" (101.2 mm) Std 1.654" (42.0 mm) Limit 1.575" (40.0 mm)
.075” (1.9 mm)
3.4
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ENGINE
Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
Cylinder / Piston / Connecting Rod
Surface warpage limit (mating with cylinder head) .0020” (0.05 mm) Cylinder bore Std 3.6221-3.6228" (92.00-92.02 mm) Taper limit .0020” (0.050 mm)
Cylinder
Piston
Piston Pin
Piston Ring Piston Ring Installed gap
Piston Ring
Connecting Rod
Crankshaft Crankshaft runout limit .0024" (.06 mm)
Out of round limit .0020” (0.050 mm)
Piston clearance
Boring Limit .020” (.5 mm)
Std 3.6204-3.6215" (91.970-91.985 mm)
Outer diameter
Standard inner diameter of piston pin bore .9055-.9057" (23.0-23.006 mm) Outer diameter .9053-.9055” (22.994-23.0 mm) Standard clearance - piston pin to pin bore .0002- .0003” (.004- .008 mm)
Degree of fit
Standard clearance - piston ring to ring groove
Connecting rod small end ID .9058 - .9063” (23.007 - 23.020 mm)
Connecting rod small end radial clearance
Connecting rod big end side clearance
Connecting rod big end radial clearance
.0098" (.25 mm) OS 3.6304-3.6310" (92.21-92.23 mm) .0197" (.50 mm) OS 3.6403-3.6407" (92.46-92.47 mm)
Top r ing
Second ring
Oil ring
Top r ing
Second ring
Std .0006-.0018" (0.015-0.045 mm)
Limit .0024" (0.060 mm)
Piston Pin must be a push (by hand) fit at 68o
F (20o C) Std .0079-.0138" (.20-.36 mm) Limit .039" (1.0 mm) Std .0079-.0138" (.20-.36 mm) Limit .039" (1.0 mm) Std .0079-.0276" (.20-.70 mm) Limit .059" (1.5 mm) Std .0016-.0031" (.040-.080 mm) Limit .0059" (.15 mm) Std .0012-.0028" (.030-.070 mm) Limit .0059" (.15 mm)
Std .0003-.0010" (.007-.026 mm) Limit .0020" (.05 mm) Std .0039-.0256" (.1-.65 mm) Limit .0315" (.80 mm) Std .0004-.0015" (.011-.038 mm) Limit .0020" (.05 mm)
EH50PLE (498cc)
3
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side.
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ENGINE
Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
Cylinder Head / Valve / Starting Clutch EH46PLE (455cc)
Rocker arm ID .8669-.8678”(22.020-22.041 mm)
Rocker Arm
Camshaft
Cylinder Head
Valve Seat Contacting width
Valve G u ide
Val ve Margin thickness
Valve
Valve Spring
Starting Clutch
(Centrifugal Clutch)
Rocker shaft OD .8656-.8661 (21.987-22.0 mm)
Rocker shaft Oil Clearance
In
Cam lobe height
Ex
Camshaft journal OD
Camshaft journal bore ID
Camshaft Oil clearance
Surface warpage limit .0020” (.05 mm) Standard height 3.855” (97.92 mm)
In
Ex
Inner Diameter .2362-.2367" (6.0-6.012 mm) Protrusion above head .689-.709" (17.5-18.0 mm)
In
Ex
Stem diameter In .2343-.2348" (5.950-5.965 mm)
Stem Oil clearance
Overall length
Overall length
Squareness
Drum I.D.
Friction Material Thickness
Std
Limit .0059" (.15 mm)
Std .0008-.0021” (.020-.054 mm) Limit .0039” (.10 mm) Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Mag 1.4935-1.4941" (37.935-37.950 mm) PTO 1.4935-1.4941" (37.935-37.950 mm) Mag 1.4963-1.4970" (38.005-38.025 mm) PTO 1.4963-1.4970" (38.005-38.025 mm) Std .0022-.0035" (.055-.090 mm) Limit .0039" (.10 mm)
Std .028" (.7 mm) Limit .055" (1.4 mm) Std .039" (1.0 mm) Limit .071" (1.8 mm)
Std .039" (1.0 mm) Limit .031" (.8 mm) Std .047" (1.2 mm) Limit .031" (.8 mm)
Ex .2341-.2346" (5.945-5.960 mm) In .0014-.0024" (.035-.062 mm) Ex .0016-.0026" (.040-.067 mm)
In 3.976" (101.0 mm) Ex 3.984" (101.2 mm) Std 1.654" (42.0 mm) Limit 1.575" (40.0 mm)
.075” (1.9 mm) Std 5.512-5.520” (140-140.2 mm) Limit 5.528” (140.4 mm) Std .059” (1.50 mm) Limit .020” (0.50 mm)
3.6
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Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
Cylinder / Piston / Connecting Rod EH46PLE (455cc)
Surface warpage limit (mating with cylinder head) .0020” (0.05 mm)
Cylinder bore Std 3.4606-3.4614" (87.90-87.92 mm) Taper limit .0020” (0.050 mm)
Cylinder
Piston
Piston Pin
Piston Ring Piston Ring Installed gap
Piston Ring
Connecting Rod
Crankshaft Crankshaft runout limit .0024" (.06 mm)
Out of round limit .0020” (0.050 mm)
Piston clearance
Boring Limit .020” (.5 mm)
Std 3.4594-3.4600" (87.870-87.885 mm)
Outer diameter
Standard inner diameter of piston pin bore .9055-.9057" (23.0-23.006 mm) Outer diameter .9053-.9055” (22.994-23.0 mm) Standard clearance - piston pin to pin bore .0002- .0003” (.004- .008 mm)
Degree of fit
Standard clearance - piston ring to ring groove
Connecting rod small end ID .9058 - .9063” (23.007 - 23.020 mm)
Connecting rod small end radial clearance
Connecting rod big end side clearance
Connecting rod big end radial clearance
.0098" (.25 mm) OS 3.4693-3.4699" (88.120-88.135 mm) .0197" (.50 mm) OS 3.4791-3.4797" (88.370-88.385 mm)
Top r ing
Second ring
Oil ring
Top r ing
Second ring
Std .0006-.0020" (0.015-0.050 mm)
Limit .0024" (0.060 mm)
Piston Pin must be a push (by hand) fit at 68o F (20o C)
Std .0079-.0138" (.20-.35 mm) Limit .039" (1.0 mm) Std .0079-.0138" (.20-.35 mm) Limit .039" (1.0 mm) Std .0079-.0236" (.20-.60 mm) Limit .059" (1.5 mm) Std .0016-.0031" (.040-.080 mm) Limit .0059" (.15 mm) Std .0012-.0028" (.030-.070 mm) Limit .0059" (.15 mm)
Std .0003-.0010" (.007-.026 mm) Limit .0020" (.05 mm) Std .0035-.0197" (.09-.50 mm) Limit .0315" (.80 mm) Std .0004-.0015" (.011-.038 mm) Limit .0020" (.05 mm)
ENGINE
3
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side.
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ENGINE
CAU T ION
Sensor
18.5 +
ft. lbs.
(25 Nm)
SPECIAL TOOLS
SPX Corporation - 1-800-328-6657 or http:// polaris.spx.com
PART NUMBER TOOL DESCRIPTION
2870390 Piston Support Block 2871043 Flywheel Puller
2871283
5131135 Water Pump Install Kit 2870569 Crankshaft Truing Stand
2870975
PV-43527 Oil Filter Wrench
Crankshaft/Water Pump
Seal Install Kit
Mity Vac™ Pressure Test
Tool
GENERAL ENGINE SERVICE
Cooling System Specifications
THERMISTOR READING DURING OPERATION
Condition
Temperature 37.3 - 39.2 k 68° F (20° C)
System
Capacity
Approx. Reading
(Min-Max)
2.25 Quarts (2.13L)
Temperature
Radiator Cap
Relief
Pressure
Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow
and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 60/40 Antifreeze/
Coolant is recommended for use in all cooling
systems, and comes pre-mixed, ready to use.
13 PSI (89.6 kpa)
3.8
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ENGINE
WARN IN G
Radiator
Water Pump
Cylinder
Cylinder
Thermostat
FLOW
Head
Cooling System
Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.
System Pressure Test
1. Remove radiator cap cover located in storage box.
2. Remove recovery bottle hose from coolant filler.
3. Connect a Mity Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.
Radiator and Coolant Flow
3
Radiator Cap Pressure Test
1. Remove radiator cap and test using a cap tester (commercially available).
2. The radiator cap relief pressure is 13 lbs (89.6 kpa).
RECOMMENDED COOLANT
Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.
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ENGINE
WARN IN G
Accessible Components
The following components can be serviced or removed with the engine installed in the frame:
• Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Cylinder Head
• Cylinder
• Piston/RIngs
• Camshaft
• Rocker Arms
• Cam Chain and Sprockets
• Water Pump / Water Pump Mechanical Seal*
The following components require engine removal for service:
• Oil pump / Oil Pump Drive Gear
• Counterbalance Shaft or Bearing(s)
• Connecting Rod
Engine Removal
IMPORTANT: Some engine repair procedures can be performed without removing the engine. Refer to “Accessible Components” for further information.
NOTE: Upon engine removal, use a mechanical lift or have an assistant help remove the engine from the vehicle to prevent personal injury or damage to
vehicle components.
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to
possible injury or death.
1. Start with a clean work area.
2. Thoroughly clean the engine and chassis.
3. Remove the following parts as required.
•Seat
• Left and Right Side Covers (Refer to Chapter 5)
• Fuel Tank Cover / Front Cab (Refer to Chapter 5)
• Fuel Tank (Refer to Chapter 4)
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
*It may be necessary to loosen engine mounts and move engine slightly to access water pump. Use the Water Pump Mechanical Seal Puller (PN 2872105) to replace mechanical seal with engine in frame.
4. Drain the engine oil and engine coolant (see Chapter
2).
NOTE: Drain and dispose of the fluids properly.
5. Remove the spark plug high tension lead.
6. Remove engine to chassis ground cable located at the starter motor mounting fastener.
7. Remove the red battery cable from the starter motor.
8. Disconnect the engine wiring harness connections near the flywheel cover (Stator).
9. Disconnect the engine coolant temperature sensor harness at the cylinder head.
3.10
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ENGINE
TPS
IAC
Fuel Line
MAP
Fuel Injector
Oil Lines
Breather
Line
10. Disconnect the engine wiring harness from the throttle body (IAC, MAP, TPS). 500 EFI
11. Remove the outer clutch cover with PVT outlet duct, drive belt, drive clutch, driven clutch and inner clutch cover (see Chapter 6).
12. Place a small catch-container under the carburetor and carefully disconnect the fuel line. 400 ONLY
13. Place a small catch-container under the fuel rail and carefully disconnect the fuel line from the rail. 500 EFI
20. Remove the (2) head pipe fasteners and disconnect the exhaust from the engine. Remove exhaust as needed.
3
21. Remove the oil lines and breather line from the engine crankcase.
14. Loosen the clamps and support bracket that secure the carburetor to the intake manifold. 400 ONLY
15. Remove the carburetor and support it out of the way. Do not allow the carburetor to hang from the throttle or choke cables. 400 ONLY
16. Loosen the clamps that attach the throttle body to the engine intake boots. Remove the throttle body and support it out of the way. Do not allow the throttle body to hang from the throttle cable. 500 EFI
17. Insert a shop towel into the intake manifold to prevent dirt from entering the intake port.
18. Remove transmission linkage rod from gear selector and secure out of the way.
19. Remove the rear PVT inlet from the engine crankcase.
22. Remove the coolant hoses from the engine. Properly dispose of any coolant drained from the engine or hoses.
23. Remove the top, front and rear engine mount fasteners.
24. With the aid of an assistant or engine lift engine and slide it out of the RH side of the vehicle frame.
NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine appears too heavy to be lifted manually.
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ENGINE
CAU T ION
Engine Installation Notes
After the engine is installed in the frame, review this checklist and perform all steps that apply.
General Items
1. Install previously removed components using new gaskets, seals, and fasteners where applicable.
2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2 or the Owner’s Safety and Maintenance Manual).
PVT System
1. Adjust center distance of drive and driven clutch. (Chapter 6)
2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6)
3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)
Transmission
1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets. Seal connections with high temp silicone sealant if required.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to top of filler neck. It may be necessary to raise the rear of
the vehicle to aid in the complete filling of the radiator.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap and squeeze coolant lines to force air out of system.
4. Again remove radiator cap and slowly add coolant to top of fill neck.
5. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temp. Check level in reservoir tank after engine is cool and add coolant if necessary.
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil.Never substitute or mix oil brands. Serious engine damage can result.
2. Use fuel with a minimum octane of 87 (R+M)/2 method.
3. Change break-in oil and filter at 20 hours or 500 miles, whichever comes first.
Cylinder Hone Selection/ Honing Procedure
Selecting a hone which will straighten as well as
remove material from the cylinder is very important.
Using a common spring loaded finger type glaze
breaker for honing is never advised. Polaris
recommends using a rigid hone or arbor honing
machine which also has the capability of oversizing.
Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
NOTE: See next page for more information on honing.
3.12
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ENGINE
CAU T ION
CAU T ION
EXAMPLE OF CROSS HATCH PATTERN
Honing To Oversize
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new oversize
piston and rings. This may be accomplished by either
boring the cylinder and then finish honing to the final bore
size, or by rough honing followed by finish honing.
For oversize honing, always wet hone using honing oil and a coarse roughing stone. Measure the piston (see
piston measurement) and rough hone to the size of the
piston. Always leave .002 - .003" (.05 - .07 mm) for finish
honing. Refer to piston-to-cylinder clearance
specifications before honing. Complete the sizing with
fine grit stones to provide the proper cross-hatch finish
and required piston clearance.
• Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the ports will expand causing uneven bore.
• After honing has been completed inspect all port opening areas for rough or sharp edges. Apply a slight chamfer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports.
Cleaning the Cylinder After Honing
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant.
3
A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:
• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2” (1.3 cm) above and below the bore at the end of each stroke.
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ENGINE
A
B
HIGH .004 (.1 mm)
HIGH .004 (.1 mm)
SUPPORT CRANKSHAFT
HERE
A
A
HIGH .002 (.05 mm)
HIGH .005 (.13 mm)
A
A
HIGH .002 (.05 mm)
HIGH .005 (.13 mm)
Crankshaft Straightening
Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand (PN 2870569). Refer to the illustrations below.
Crankshaft Truing Stand
(PN 2870569)
NOTE: The rod pin position in relation to the dial
indicator position tells you what action is required to straighten the shaft.
1. To correct a situation like the one shown in the illustration, strike the shaft at point A with a brass hammer.
3. If the crank rod pin location is 180o from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at position A as shown in the illustration at right. When rebuilding and straightening a crankshaft, runout must be as close to zero as possible.
NOTE: Maximum allowable runout is .0024”.
Engine Lubrication
Oil Type:Polaris Premium 4 Synthetic or API certified “SH” 2W-50 oil
Capacity: . . . . . . . Approximately 2 U.S. Quarts (1.9 l)
Filter Wrench . . . . (PV-43527)
*Drain Plug / Screen Fitting...14 ft. lbs. (19 Nm) (If fitting is removed, follow oil pump priming procedure).
*Oil Pressure Specification...20 PSI @ 5500 RPM, Polaris 2W-50 Synthetic (Engine Hot)
Oil Pressure Test
1. Remove blind plug on front left cylinder head.
2. Insert a 1/8 NPT oil pressure gauge adaptor into the cylinder head and attach the gauge.
3. Start engine and allow it to reach operating temperature, monitoring gauge indicator.
NOTE: Use only Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281).
2. To correct a situation like the one shown in the illustration, squeeze the crankshaft at points A. (Use tool from alignment kit).
3.14
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Oil Pressure at 5500 RPM (Engine Hot):
Standard: 20 PSI Minimum: 12 PSI
Page 70
ENGINE
Vent Hose
Oil Tank
Oil Filter
Oil feed to filter
From filter to
One way valve
crankshaft
Top fitting is oil feed or intake from bottom of tank
Bottom fitting is oil exhaust or return to tank
Internal passage to camshaft (front left head bolt)
Oil Flow
The following chart describes the flow of oil through the engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. 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. (When the engine is off, the one way valve closes to prevent oil in the tank from draining into the crankcase.) The oil is pumped through a delivery pipe to the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
At this point, the oil is diverted in two directions. Oil is supplied to the camshaft through the left front cylinder stud, and an oil passage in the head. Oil enters the camshaft through the PTO (L) journal. The camshaft journals, cam lobes, and rocker arms are lubricated through holes in the camshaft. The oil lubricates the cam chain and sprocket and drains to the sump.
The other oil path from the filter leads through a delivery pipe to the crankcase main oil gallery, which leads to the stator plate oil passage. Here it passes through the slotted friction bearing (located in the stator plate) into the crankshaft. An oil seal on the stator plate prevents oil from entering the stator/flywheel area. Oil travels through the crankshaft to the crank pin, lubricating the connecting rod large end bearing directly. Oil also passes through an oil jet (drilled orifice) in the end of the crank pin to the PTO end main bearings and counterbalancer gears.
Residual oil from the lubrication of the crankshaft and connecting rod indirectly lubricates the cylinder wall, piston, rings, connecting rod small end bearing, piston pin, oil/water pump drive gears, cam chain and drive sprocket, and Magneto end crankshaft main bearing.
The one-way valve is located on the front left (PTO) side of the crankcase. The valve prevents oil in the tank from draining into the engine sump when the engine is off. The valve mechanism consists of a plunger, return spring, guide plug, and sealing washer. When the engine is running, oil pressure lifts the plunger off the seat, allowing oil flow. When the engine is off, spring pressure forces the plunger against the oil passage seat, preventing oil flow from the tank to the sump. The one-way valve requires very little maintenance. If engine oil drains into the sump when the engine is off, inspect the valve sealing surface for debris or damage. Inspect the return spring for distortion or damage.
3
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ENGINE
Oil Tank
Oil Hose
Crankcase
Oil Gallery
Crankcase
Oil Gallery
Oil Pump (Scavenging)
Oil Hose
Oil Strainer
Crankcase
Oil Gallery
Oil Pump
(Feed)
One Way Valve
Bypass
Oil Filter
Delivery Pipe
Crankshaft
Prevents oil from
draining into crankcase with
engine off
Top of Oil Tank
Delivery Pipe
Delivery Pipe
Crank Pin
Large End Bearing
Cylinder Sleeve
Small End Bearing
Crankcase
(PTO)
Main Bearing
Cam Shaft Journal
Cam Lobe
Cam Shaft Journal
Chain Room
Sprocket Chain
Metal
Union Fitting (Lower)
Union Fitting (Upper)
Through Cylinder Stud Front Left
Oil Jet
Indirect Lubrication
Screen Fitting (Bottom of Tank)
Rocker Arm Rocker Shaft
Oil Flow Diagram
3.16
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Engine Exploded Views
Crankshaft
Cylinder/
and Piston
Cylinder Head
Crankcase
Valvetrain
ENGINE
3
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Page 73
ENGINE
TDC “T” Mark
Rotation
Advance Marks
B
A
ENGINE DISASSEMBLY
Cam Chain Tensioner / Rocker Arm / Camshaft Removal
1. Remove ignition timing inspection plug from recoil housing.
To position crankshaft at Top Dead Center (TDC) on compression stroke:
2. Rotate engine slowly in the direction of rotation watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching camshaft sprocket marks and the mark in the timing inspection hole.
4. Align single (TDC) mark on flywheel with projection in inspection hole, and the cam sprocket pin (facing upward) aligned with the camshaft to crankshaft center line.
NOTE: The cam lobe should be pointing down and valves should have clearance at this point.
5. Remove cam chain tensioner plug, sealing washer, and spring. CAUTION: The plug is under spring tension. Maintain inward pressure while removing.
6. Remove the two 6x25 mm cam chain tensioner flange bolts.
7. Tap lightly on tensioner body with a soft face hammer and remove tensioner.
3.18
Cam Chain Tensioner Inspection
1. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth on ratchet pawl (A) and plunger teeth (B) for wear or damage.
2. Push ratchet pawl and hold it. The plunger should move smoothly in and out of the tensioner body.
3. Release ratchet pawl and push inward on plunger. It should remain locked in position and not move inward.
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Tensioner Spring Free Length:
2.02” (5.13 cm)
4. Measure free length of tensioner spring. Replace spring if excessively worn. Compare to specifications.
5. Replace entire tensioner assembly if any part is worn or damaged.
ENGINE
3. Measure O.D. of rocker shaft. Inspect it for wear or damage. Compare to specifications.
3
Rocker Shaft O.D.:
.8656-.8661” (21.987-22.0 mm)
4. Measure I.D. of each rocker arm and compare to specifications.
Rocker Arm / Shaft Inspection
1. Mark or tag rocker arms to keep them in order for assembly.
2. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm.
NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged.
5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications.
Rocker Arm & Support I.D.:
.8669-.8678” (22.020-22.041 mm)
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ENGINE
Sprocket teeth
Inspect for Areas of Tooth
Wear or Damage
6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D. This is the oil clearance. Compare to specifications.
Rocker Shaft Oil Clearance:
Std: .0008 - .0021” (.020 - .054 mm)
Limit: .0039” (.10 mm)
7. Inspect rocker adjuster screws for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts.
NOTE: The end of the adjuster screw is hardened and cannot be ground or re-faced.
Camshaft Removal
1. Remove thermostat housing.
5. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged.
6. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts.
7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain.
2. Remove camshaft sprocket inspection cover.
3. Loosen three camshaft sprocket bolts.
4. Remove camshaft end cap and O-ring.
3.20
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8. Secure cam chain with a wire to prevent it from falling into the crankcase.
9. Inspect cam sprocket teeth for wear or damage. Replace if necessary.
Page 76
ENGINE
Decompressor Shaft
Decompressor Ball
Retainer Sleeve
B
A
C
Stop Pin
Spring in relaxed position
Figure 3.21
10. Slide camshaft out the PTO side of the cylinder head.
Automatic Compression Release Removal / Inspection
NOTE: The automatic compression release mechanism can be inspected and serviced without removing the camshaft from the cylinder head. The actuator ball in the camshaft is not replaceable. Replace the camshaft as an assembly if the actuator ball is worn or damaged.
Automatic Compression Release Installation
1. Slide spring onto shaft.
2. Apply engine oil to release lever shaft.
The actuator ball must be held outward to allow installation of the release lever shaft.
3
1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.
2. Remove release lever shaft and return spring.
3. Inspect shaft for wear or galling.
4. Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary.
If Camshaft is Removed From Engine:
3. Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft.
If Camshaft is Installed in the Engine:
4. Use a small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft.
5. Position camshaft as shown at the bottom of Figure
3.21.
6. Place arm of spring under stop pin as shown and push release lever inward until fully seated. Do not pre­wind the spring one full turn or the compression release will not disengage when the engine starts. Check operation of mechanism as outlined in Step 1 of Removal (above). NOTE: When shaft is properly installed, actuator ball will be held in the “out” position. It is important to note that spring pressure is very light.
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ENGINE
Lubrication holes
Lobe height
Journal O.D.
Journal
B
Camshaft Inspection
1. Visually inspect each cam lobe for wear, chafing or damage.
2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed.
Cam Lobe Height (Intake & Exhaust):
Std: 1.2884-1.2924” (32.726-32.826 mm)
Limit: 1.2766” (32.426 mm)
3. Measure height of each cam lobe using a micrometer. Compare to specifications.
Calculate oil clearance by subtracting journal OD from journal bore ID. Compare to specifications.
Camshaft Oil Clearance:
Std: .0022-.0035” (.055-.090 mm)
Limit: .0039” (.10 mm)
NOTE: Replace camshaft if damaged or if any part is worn past the service limit.
NOTE: Replace cylinder head if camshaft journal bore is damaged or worn excessively.
Cylinder Head Removal
1. Remove the two 6mm flange bolts (A) from cylinder head. See exploded view on next page.
2. Loosen each of the four cylinder head bolts evenly 1/8 turn each time in a criss-cross pattern until loose.
3. Remove bolts (B) and tap cylinder head lightly with a plastic hammer until loose.
IMPORTANT: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the thread.
Camshaft Journal O.D.:
Mag & PTO End: 1.4935-1.4941”
(37.935-37.950 mm)
4. Measure camshaft journal outside diameter (O.D.)
5. Measure ID of camshaft journal bore.
3.22
Camshaft Journal I.D.:
Mag & PTO End: 1.4963-1.4970”
(38.005-38.025 mm)
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4. Remove cylinder head and head gasket.
Page 78
Cylinder Head Exploded View
B
A
ENGINE
3
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ENGINE
B
WARN IN G
C
D
Cylinder Head Inspection
Thoroughly clean cylinder head (B) surface to remove all traces of gasket material and carbon.
CAUTION: Use care not to damage sealing surface.
Cylinder Head Warpage
Lay a straight edge across the surface of the cylinder head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface. If warpage exceeds the service limit, replace the cylinder head.
Cylinder Head Disassembly
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their location in the cylinder head.
1. Using a valve spring compressor (C), compress the valve spring and remove the split keeper.
NOTE: To prevent loss of tension, do not compress the valve spring more than necessary.
Cylinder Head Warpage Limit:
.002” (.05 mm)
2. Remove spring retainer and spring.
NOTE: The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs (D).
3. Push valve out, keeping it in order for reassembly in the same guide.
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ENGINE
A
B
Measure valve stem in
several places
4. Measure free length of spring with a Vernier caliper. Check spring for squareness. Compare to specifications. Replace spring if either measurement is out of specification.
5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
Valve Inspection
1. Remove all carbon from valve with a soft wire wheel.
4. Inspect split keeper groove for wear or flaring of the keeper seat area (B).
NOTE: The valves cannot be re-faced or end ground. They must be replaced if worn, bent, or damaged.
5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Compare to specifications.
3
Valve Stem Diameter:
Intake: .2343-.2348” (5.950-5.965 mm)
Exhaust: .2341-.2346” (5.945-5.960 mm)
6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side.
2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.
3. Check end of valve stem for flaring, pitting, wear or damage (A).
Valve Guide I.D.:
.2362 - .2367” (6.0 - 6.012 mm)
7. Subtract valve stem measurement to obtain stem to guide clearance.
NOTE: Be sure to measure each guide and valve combination individually.
8. Replace valve and/or guide if clearance is excessive. Compare to specifications.
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ENGINE
CAU T ION
Too Uneven Good Too Wide Narrow
NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to the “Valve Seat Reconditioning” procedure.
Combustion Chamber
Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush.
Valve Seat Reconditioning
Valve Guide Removal / Installation
1. Remove all carbon deposits from the combustion chamber, valve seat and valve guide area before attempting to remove valve guides. CAUTION: Carbon deposits are extremely abrasive and may damage the valve guide bore when guides are removed.
2. Place new valve guides in a freezer for at least 15 minutes while heating cylinder head.
3. Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212° F (100° C). CAUTION: Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.
Follow the manufacturer’s instructions provided with the valve seat cutters in commercially available valve seat reconditioning kits. Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced.
Cylinder Head Reconditioning
NOTE: Servicing the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques. Follow the instructions provided in the cylinder head service tool kit.
Wear eye protection when performing cylinder
head service. Valve guide replacement will
require heating of the cylinder head.
Wear gloves to prevent burns.
NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced and the valve may overheat and warp, resulting in burnt valves.
4. When thoroughly heated, place cylinder head on blocks of wood which will allow the old guides to be removed.
5. Using valve guide driver, drive guides out of the cylinder head from the combustion chamber side. Be careful not to damage guide bore or valve seat when removing guides.
6. Place cylinder head on cylinder head table.
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NOTE: Be sure cylinder head is still at 212° F (100° C) before installing new guides.
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ENGINE
Valve Guide Installed Height
A
7. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height of each guide above the cylinder head (A).
Valve Guide Height:
.689 - .709” (17.5 - 18.0 mm)
NOTE: The guide can also be driven in to the proper depth. Inspect the guide closely for cracks or damage if a driver is used.
Reaming The Valve Guide
8. Allow cylinder head to cool to room temperature. Apply cutting oil to the reamer. Guides should be reamed from the valve spring side of the cylinder head. Ream each guide to size by turning the reamer clockwise continually. Continue to rotate reamer clockwise during removal of the tool.
12. Place 46o cutter on the pilot and make a light cut.
3
13. Inspect the cut area of the seat.
• If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180o and
make another light cut.
• If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.
• If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be replaced. Be sure the cylinder head is at the proper temperature and replace the guide.
9. Clean guides thoroughly with hot soapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.
10. Install pilot into valve guide.
11. Apply cutting oil to valve seat and cutter.
• If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident.
NOTE: Remove only the amount of material necessary to repair the seat surface.
14. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46o) apply black permanent marker to the entire valve face (A).
15. Insert valve into guide and tap valve lightly into place a few times.
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ENGINE
Seat
Width
Bottom - 60o or 75
o
Seat - 45o or 46
o
Top - 30
o
or 31
o
A
16. Remove valve and check where the Prussian Blue™ indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.
• If the indicated seat contact is at the top edge of
the valve face and contacts the margin area it is too high on the valve face. Use the 30o cutter to
lower the valve seat.
• If too low use the 60o or 75o cutter to raise the
seat. When contact area is centered on the valve face, measure seat width.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45o cutter
and re-check contact point on the valve face and seat width after each cut.
Valve Seat Width:
Intake Std: .028” (.7 mm)
Limit: .055” (1.4 mm)
NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point on the black marked area, all the way around the valve face.
17. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.
18. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Lapping is not required with an interference angle.
19. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.
20. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s).
21. Clean cylinder head, valves, and camshaft oil supply passage (A) thoroughly.
Exhaust Std: .039”(1.0 mm)
Limit: .071” (1.8 mm)
22. If oil passage blind plug was removed, apply Crankcase Sealant (PN 2871557) or equivalent sealer to the threads and install, torquing to 8 ft. lbs. (11 Nm). CAUTION: Do not allow sealant to enter oil passage.
23. Spray electrical contact cleaner into oil passage and dry using compressed air.
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ENGINE
CAU T ION
Feeler Gauge for Both Valves
Cylinder Head Assembly
Wear eye protection during assembly.
NOTE: Assemble the valves one at a time to maintain proper order
1. Install new valve seals on valve guides.
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid damaging valve seal.
6. Place retainer on spring and install valve spring compressor. Compress spring only enough to allow split keeper installation to prevent loss of spring tension. Install split keepers with the gap even on both sides.
7. Repeat procedure for remaining valve.
8. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.
Valve Sealing Test
1. Clean and dry the combustion chamber area.
2. Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.
3. Repeat for exhaust valves by pouring fluid into exhaust port.
Valve Clearance Adjustment
NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.
1. Insert .006” feeler gauge(s) between end of the valve stem and adjuster screw(s).
3
5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
2. Loosen locknut(s) and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/ Clutch Adjuster Tool (PA-44689) can be used to adjust the engine valves.
NOTE: Both feeler gauges should remain inserted during adjustment of each exhaust valve.
VALVE CLEARANCE
.006” (.15 mm)
3. When clearance is correct, hold adjuster screw and tighten locknut securely.
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ENGINE
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.
Cylinder / Piston Removal and Inspection
NOTE: Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head.
1. Remove cam chain guide at front of cylinder.
2. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Remove the pipes.
3. Loosen hose clamps and remove coolant inlet hose.
4. Remove the two 6 mm cylinder base bolts.
5. Loosen each of the four large cylinder base bolts 1/4 turn at a time in a criss-cross pattern until loose and remove bolts.
3.30
NOTE: The bolts are inside the water jacket.
6. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose.
7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN
2870390).
8. Remove dowel pins from crankcase.
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ENGINE
A
Piston Removal
1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine.
2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.
3. Remove top compression ring.
4. Repeat procedure for second ring.
The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (A) in the upper oil ring land of the piston.
3
5. Remove the top rail first followed by the bottom rail.
6. Remove the expander.
*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.
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ENGINE
1/2” Down From Top of Cylinder
1/2” Up From Bottom
X
X
X
Y
Y
Y
CAU T ION
Cylinder Inspection
1. Remove all gasket material from the cylinder sealing surfaces.
2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge.
Cylinder Warpage:
.002” (.05 mm)
5. Record measurements. If cylinder is tapered, or out of round beyond .002, the cylinder must be re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
(EH500PLE 498cc )
3.6221 - 3.6228” (92.00 - 92.012 mm)
(EH46PLE 455cc Carbureted)
3.4606-3.4614" (87.90-87.92 mm)
Cylinder Hone Selection / Honing Procedure
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2" down from top, in the middle, and 1/2" up from bottom).
Selecting a hone which will straighten as well as
remove material from the cylinder is very
important. Using a common spring loaded finger
type glaze breaker for honing is never advised.
Polaris recommends using a rigid hone or arbor
honing machine which also has the
capability of oversizing.
Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
NOTE: See next page for more information on honing.
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ENGINE
CAU T ION
CAU T ION
EXAMPLE OF CROSS HATCH PATTERN
Honing to Oversize
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
oversized piston and rings. This may be
accomplished by either boring the cylinder and
then finish honing to the final bore size, or by
rough honing followed by finish honing.
For oversize honing always wet hone using
honing oil and a coarse roughing stone.
Measure the piston (see piston measurement) and rough hone to the size of the piston. Always leave .002 - .003" (.05 - .07 mm) for finish honing.
Refer to piston-to-cylinder clearance
specifications on Page 3.5 before honing.
Complete the sizing with fine grit stones to
provide the proper cross-hatch finish and
required piston clearance.
• Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the ports will expand causing uneven bore.
• After honing has been completed inspect all port opening areas for rough or sharp edges. Apply a slight chamfer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports.
3
Cleaning the Cylinder After Honing
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant.
A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:
• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stone approximately 1/2" (1.3 cm) beyond the bore at the end of each stroke.
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ENGINE
Piston
Piston Pin
40 mm
Piston Pin Bore
Piston Pin Measurement Locations
Piston-to-Cylinder Clearance
1. Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin.
2. Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above.
Piston to Cylinder Clearance
E H 5 0 0 P L E ( 4 9 8 c c )
Std: .0006-.0018” (.015-.045 mm)
Piston / Rod Inspection
1. Measure piston pin bore.
Piston Pin Bore:
.9055 - .9057” (23.0 - 23.006 mm)
2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance.
E H 4 6 P L E ( 4 5 5 c c )
Std: .0006-.0028” (.015-.050 mm)
Piston O.D.:
E H 5 0 0 P L E ( 4 9 8 c c )
Std: 3.6204-3.6215” (91.970-91.985 mm)
E H 4 6 P L E ( 4 5 5 c c )
Std: 3.4594-3.4600” (87.870-87.885 mm)
Piston Pin O.D.
.9053 - .9055” (22.994 - 23.0 mm)
3. Measure connecting rod small end ID.
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ENGINE
Piston
Ring
Feeler Gauge
Feeler Gauge
Piston ring
Cylinder
25-50 mm
4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to­groove clearance exceeds service limits.
Piston Ring-to-Groove Clearance
Top Ring Std: .0016-.0031" (.040-.080 mm)
Limit: .0059" (15 mm)
Second Ring Std: .0012-.0028" (.030-.070 mm)
Limit: .0059" (15 mm)
Piston Identification
The piston may piston may not placement. If the piston has an identification mark, fol-
low the directions for piston placement below. If the pis­ton does not have an identification mark, the direction for placement of the piston does not matter.
Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “g”, “ 4” or “:” must always be toward the flywheel side of the engine. The
other numbers are used for identification as to diameter, length and design. Four stroke engine rings have a rectangular profile. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings.
*Pistons and rings marked 25 equal .25mm (.010”) over­sized
*Pistons and rings marked 50 equal .50mm (.020”) oversized
have an identification mark or the
have an identification mark for piston
Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right.
2. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder.
3
Piston Ring Installed Gap
Top Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Second Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Oil Ring
Std: .0079-.0276" (.20-.70 mm)
Limit: .059" (1.5 mm)
NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.
3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is below specified limit, file ring ends until gap is within specified range.
NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with an oiled rag immediately to remove residue and prevent rust.
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ENGINE
A
B
C
Crankcase Disassembly
NOTE: The recoil starter, starter motor, starter drive, flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame.
Starter Drive Removal / Inspection
1. Remove recoil housing bolts and remove housing.
2. Remove starter drive assembly. Note the thrust washer located at the rear of the drive mechanism.
3. Inspect the thrust washer for wear or damage and replace if necessary.
Starter Drive Bushing Clearance:
Std: .0015”-.004” (.038-.102 mm)
Service Limit:
.008” (.203 mm)
6. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.
Flywheel and Stator Removal / Inspection
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PN 2871043) and remove flywheel. CAUTION: Do not thread the puller bolts into the flywheel more than 1/4" or stator coils may be damaged.
3. Mark or note position of stator plate on crankcase.
4. Remove bolts and carefully remove stator assembly, being careful not to damage crankshaft bushing on stator plate.
5. Replace crankshaft seal (B).
4. Measure the OD of the starter drive shaft on both ends and record.
5. Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90o apart to determine if bushing is out of round. Calculate bushing clearance. Replace bushing if clearance exceeds the service limit.
Std. Bushing ID:
.4735”-.4740” (11.11-12.04 mm)
Std. Shaft OD:
.470”-.472” (11.93-11.99 mm)
6. Remove oil passage O-Ring (C).
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ENGINE
D
E
7. Remove large sealing O-Ring from outer edge of stator plate.
Cam Chain / Tensioner Blade
1. Remove bolt securing tensioner blade to crankcase (D).
3. Remove cam chain (E). Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch section of chain. Replace if worn past service limit.
3
Chain Service Limit:
5.407” (13.7 cm)
4. Using the special socket, remove the crankshaft slotted nut.
NOTE: The slotted nut is a left hand thread.
2. Remove blade and inspect for cracks, wear, or damage.
5. Remove cam chain drive sprocket and woodruff key from crankshaft.
6. Inspect sprocket teeth for wear or damage.
7. Inspect woodruff key for wear.
8. Replace any worn or damaged parts.
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ENGINE
D
C
B
A
CAU T ION
C
B
A
One Way Valve
The one way valve prevents oil from draining out of the oil tank and into the crankcase when the engine is off. It must be clean and have adequate spring pressure in order to seal properly.
1. Remove cap bolt (A), sealing washer (B), spring (C), and one way valve (D) from PTO side crankcase.
2. Inspect free length of spring and check coils for distortion.
One Way Valve Spring Free Length:
3. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase. Watch the gap along the crankcase mating surface and separate the crankcase evenly. It may also be necessary to tap the oil pump shaft lightly to separate the crankcase.
Do not strike the oil pump shaft at an angle or the
shaft may bend, causing irreparable damage.
Tap only lightly on the pump shaft if necessary.
4. Remove the Mag (RH) crankcase from the PTO case.
Oil Pump Removal / Inspection
1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft.
Std: 1.450” (3.68 cm)
3. Inspect valve for wear.
4. Check seat area for nicks or foreign material that may prevent proper sealing of valve.
Crankcase Separation
1. Remove flange bolts (10) from magneto side crankcase evenly in a criss-cross pattern.
2. Separate crankcase by tapping with a soft faced hammer in reinforced areas.
2. Remove (2) bolts holding pump drive gear (C).
3. Inspect drive gear teeth for cracks, damage or excessive wear.
4. Remove three oil pump retaining bolts and pump.
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ENGINE
5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities.
6. Remove the three screws and strainer screen from pump.
7. Clean screen thoroughly.
8. Remove pump body screw and feed chamber cover.
9. Measure pump end clearance using a feeler gauge and straight edge.
3
Pump End Clearance:
Std: .001-.003 (.0254-.0762 mm)
Wear Limit: .004 (.1016 mm)
10. Measure rotor tip clearance with a feeler gauge.
Rotor Tip Clearance:
Std: .005 (.127 mm)
Wear Limit: .008 (.2032 mm)
11. Remove inner and outer feed rotor and pump chamber body.
12. Repeat measurements for scavenge rotor.
13. Remove inner and outer scavenge rotor and inspect pump shaft for wear.
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ENGINE
A
Oil Pump Assembly
1. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged.
2. Install pump shaft and scavenge rotor drive pin.
3. Install outer scavenge rotor, inner scavenge rotor, and scavenge casing.
4. Install outer feed rotor and inner feed rotor drive pin.
5. Install inner feed rotor and feed chamber cover with screw.
6. Tighten screw securely.
7. Install screen on pump body.
8. Install oil pump on crankcase and torque bolts to 6 ft. lbs. (8 Nm).
Oil Pump Attaching Bolt Torque:
6 ft. lbs. (8 Nm)
2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned during reassembly.
3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft from the crankcase.
Counter Balancer Shaft Removal / Inspection
1. Remove the shim washer (A) from the counter balancer shaft.
4. Inspect the balancer drive gear and pump shaft drive gear.
5. Replace the shaft if gear teeth are abnormally worn or damaged.
6. Inspect the balancer shaft bearings.
NOTE: Due to extremely close tolerances and minimal wear, the balancer shaft ball bearings must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.
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ENGINE
C
Crankshaft Removal / Inspection
1. Remove the shim washer (C) from the crankshaft.
2. Support the PTO side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod.
3. Use a feeler gauge to measure the connecting rod big end side clearance.
5. Measure the connecting rod big end radial clearance.
Big End Radial Clearance:
Std: .0004-.0015” (.011-.038 mm)
Limit: .0020” (.05 mm)
6. Inspect the crankshaft main bearing journals for scoring and abnormal wear.
3
Connecting Rod Big End Side Clearance:
Std: .0039-.0256” (.1-.65 mm)
Limit: .0315” (.80 mm)
4. Place the crankshaft in a truing stand or V-blocks and measure the runout on both ends with a dial indicator.
Max Runout: .0024” (.06 mm)
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ENGINE
Crankcase Bearing Inspection
1. Remove the seal from the PTO side crankcase.
2. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.
3. Support the crankcase and drive or press the main bearings out of each crankcase.
4. To remove balancer shaft bearings and pump shaft bearing use a blind hole bearing puller.
NOTE: Bearings are stressed during the removal process and should not be re-used!
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
NOTE: The water pump mechanical seal can be removed without removing the engine. Refer to Water Pump Mechanical Seal Installation.
Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled.
1. Remove the pump shaft bearing from the Magneto (right hand) side crankcase.
2. Pry out the oil seal, noting the direction of installation with the spring side facing IN (toward inside of case).
3. Drive the water pump mechanical seal out of the crankcase from inside to outside. Note: The new mechanical seal must be installed after the crankcases are assembled, using a special tool. See Mechanical Seal Installation.
Crankcase Inspection
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1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.
2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged.
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ENGINE
Bearing Installation
NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer.
1. Install the bearings so the numbers are visible.
2. Drive or press new bearings into the crankcases, using the proper driver. CAUTION: Press only on outer race of bearing to prevent bearing damage.
• 70 mm (2.755") driver- for crankshaft main
bearings.
• 46 mm (1.810") for counter balancer bearings.
• 28 mm (1.100") for pump shaft bearing.
End Play Inspection / Adjustment
Before reassembling the crankcase the following steps should be performed to determine the amount of crankshaft, counter balancer shaft, and pump shaft end play: Excessive end play may cause engine noise at idle and slow speeds. Too little play will side load the bearings which may lead to premature bearing failure.
Crankshaft End Play Adjustment
1. Make sure all bearings are firmly seated in both the Mag and PTO crankcase.
3
2. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge.
3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record.
PTO Case Depth______________________
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ENGINE
4. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record.
5. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record.
8. Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6, and record below.
Total End Play______________________
9. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed below.
Crankshaft End Play:
.008”-.016” (.02-.04 cm)
Counter Balancer Shaft End Play Adjustment
1. Make sure all bearings are firmly seated in the crankcase.
2. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading.
Mag Case Depth______________________
6. Add the readings recorded in Step 3 and Step 5 and record below.
Total Case Width______________________
7. Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record.
Crankshaft Width______________________
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3. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.
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ENGINE
4. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1, 2, and 3.
5. Add the readings obtained in Step 3 and Step 4.
6. Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step 5.
7. Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed. The result must be within the specified range listed at below.
Counter Balancer Shaft End Play:
.008”-.016” (.02-.04 cm)
Oil Pump Shaft End Play Adjustment
1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase.
2. Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.
4. Subtract the thickness of the existing shim from the result of Step 3 to determine if a different shim is needed. See “Pump Shaft End Play” specification below.
Pump Shaft End Play:
.008”-.016” (.02-.04 cm)
ENGINE REASSEMBLY
Pump Shaft Oil Seal Installation
1. Install the seal from the outside of the crankcase (water pump side) with the spring facing inward, toward the pump shaft bearing.
3
3. Install the gear on the oil pump and measure the width of the pump and gear. Subtract this measurement from the measurement recorded in Step 2.
2. Drive or press the seal into place using a 25 mm (.985") seal driver, until flush with the outer edge of the seal bore.
3. Lubricate the seal lip with grease.
Crankshaft / Counter Balance / Oil Pump Installation
Lubricate all bearings with clean engine oil before assembly.
Use the Crankshaft/Water Pump Installation Kit (PN
2871283) to prevent damage to the crankshaft and main
bearings during installation.
1. Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the threads are engaged a minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the threaded rod. Hold the crankshaft and tighten the nut to draw the crankshaft into the main bearings until fully seated. Loosen the nut and remove the threaded rod from the crankshaft. If removal is difficult, install two nuts on the end of the threaded rod and tighten against each other.
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