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
Length83 in. / 210.8 cm
Width48 in. / 121.9 cm
Height48 in. / 121.9 cm
Wheel Base50.75 in. / 128.9 cm
Ground Clearance11.25 in. / 28.6 cm
Dry Weight688 lbs. / 312 kg
Front Rack Capacity90 lbs. / 41 kg
Rear Rack Capacity180 lbs. / 81.6 kg
Towing Capacity1225 lbs. / 555.7 kg
Max. Weight Capacity485 lbs. / 220 kg
Hitch Tongue Weight120 lbs. / 34 kg
Unbraked Trailer Towing
Capacity (EU)
Data based on EU
Directive: 76/432/EEC
1786 lbs. / 810 kg
Engine
PlatformFuji 4-cycle, L/C, Single Cyl.
Engine Model NumberEH460PLE050
Engine Displacement455cc
Number of Cylinders1
Bore & Stroke (mm)87.9 x 75 mm
Compression Ratio10.1:1
Compression Pressure 50-90 psi
Engine Idle Speed 1200+/- 200 RPM
Engine Max Speed7000 RPM
Cooling System / Cap.Liquid / 2.7 qt. (2.5 L)
Overheat WarningHOT on Instrument Cluster
LubricationDry Sump
Oil RequirementsPS-4 Plus / 2 qt. (1.9 L)
Exhaust SystemSingle Pipe - USFS Approved
Carburetion
Carburetor modelMikuni BST 34mm
Main Jet160
Pilot Jet / Pilot Air Jet42.5 / 160
Jet Needle4IB33-3
Needle JetP-6M
Pilot / Air Screw2.75 Turns Out (Initial setting)
Float Height13mm from carburetor body
Fuel DeliveryFuel Pump (Impulse)
Fuel Capacity / 4.25 gal. (16 L)
Fuel Requirement
MODEL NUMBER:
A12MH50AX, AZ, AD, AQ, FF, FY, FX
ENGINE MODEL: EH500PLE13B
CategoryDimension / Capacity
Length83 in./210.8 cm
Width48 in./121.9 cm
Height48 in./121.9 cm
Wheel Base50.75 in./128.9 cm
Ground Clearance11.25 in./28.6 cm
Dry Weight696 lbs./313 k g
(Wet weight model FF, FY,
FX)
776 lbs / 352 kg)
Front Rack/Box Capacity90 lbs./40.8 kg
Rear Rack Capacity180 lbs./81.6 kg
Max. Weight Capacity485 lbs. / 220 kg
Towing Capacity1225 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
PlatformFuji Single Cylinder
Engine Model NumberEH500PLE13B
Engine Displacement498cc
Number of Cylinders1
Bore & Stroke (mm)92 x 75 mm
Compression Ratio10.2:1
Compression Pressure70-90 psi W/Compression
CategoryDimension / Capacity
Length86 in./218 cm
Width48 in./122 cm
Height48 in./122 cm
Wheel Base57 in./145 cm
Ground Clearance11 in./28 cm
Dry Weight723 lbs./328 kg
Front Rack/Box Capacity90 lbs./40.8 kg
Rear Rack Capacity180 lbs./82 kg
Max. Weight Capacity485 lbs. / 220 kg
Towing Capacity1225 lbs. / 555.7 kg
Unbraked Trailer Towing
Capacity (EU)*
NOTE: *Data based on
EU Directive: 76/432/EEC
Hitch Tongue Capacity120 lbs./54.4 kg
1995 lbs. / 905 kg
Rear rack capacity and
tongue weight not to
exceed 180 lbs./82 kg
ENGINE
PlatformFuji Single Cylinder
Engine Model Number EH500PLE13B
Engine Displacement498cc
Number of Cylinders1
Bore & Stroke (mm)92 x 75 mm
Compression Ratio10.2:1
Compression Pressure70-90 psi W/Compression
CategoryDimension / Capacity
Length83 in./210.8 cm
Width48 in./121.9 cm
Height48 in./121.9 cm
Wheel Base50.75 in./128.9 cm
Ground Clearance11.25 in./28.6 cm
WET Weight807 lbs. / 366 kg
Front Rack/Box Capacity85 lbs./39 kg
Rear Rack Capacity180 lbs./81.6 kg
Max. Weight Capacity485 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 Capacity120 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
PlatformFuji 4 stroke, Single Cylin-
der
Engine Model NumberEH500PLE216
Engine Displacement498cc
Number of Cylinders1
Bore & Stroke (mm)92 x 75 mm
Compression Ratio10.2:1
Compression PressureCompression Release 50-
90 psi
Engine Idle Speed 1150 ± 50 RPM
Max Engine Speed7000 RPM
Cooling System / CapacityLiquid / 2.7 qts (2.5 L)
Overheat WarningHOT on Instrument Clus-
ter
LubricationPressurized Dry Sump
Oil Requirements / Capac-
ity
Exhaust SystemSingle Pipe
Fuel System
Carburetor modelElectronic Fuel Injection
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.
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
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
* 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 greaseSemi-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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
• 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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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).
Page 36
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
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
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.
2.20
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
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).
2.22
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
Page 42
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
2.24
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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)
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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)
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
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
• 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.
2.28
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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)
FrontRear
5 (34.5 Kpa)5 (34.5Kpa)
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
• 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.
2.32
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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).
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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).
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
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
3.24
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
3.26
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
NOTE: Be sure cylinder head is still at 212° F
(100° C) before installing new guides.
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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).
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.
3.28
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
3.32
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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).
3.36
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
3.38
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
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.
3.40
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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
3.42
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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______________________
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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______________________
3.44
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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.
Page 100
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.
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.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual