2004 – 2014 Polaris 400, 450, 500 Sportsman Carburated ATV Online Service Manual

The Cyclepedia Polaris Sportsman 400, 450, and 500 Online Service Manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran ATV technician. PLUS you get tech support with a real live person, should you need it.

Polaris ATV Coverage

Polaris Sportsman 400 (Late 2004 – 2005)
Polaris Sportsman 400 HO (2011 – 2014)
Polaris Sportsman 500 HO (2001 – 2006, 2008 – 2014)
Polaris Sportsman 450 (2006 – 2007)
Polaris Sportsman 450 Browning Edition (2006)
Polaris Sportsman 500 (Late 2004 – 2014)

Carburetor Equipped Standard model Sportsman ATVs: Late 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014

Table of Contents

Service Information
Quick Reference
Special Tools
Specifications
Torque Specifications
VIN and Engine Number Location

Periodic Maintenance
Service Interval
Periodic Maintenance Chart
Brake Fluid
Air Filter Servicing
Brake Inspection
Compression Test
Engine Idle Speed
Engine Oil
Front Gearcase Oil
Fuel Hose Inspection
Lubrication
Spark Arrestor
Spark Plug
Throttle Free Play
Tires
Steering Inspection
Transmission Linkage Inspection
Transmission Oil
Valve Adjustment

External Components
Bumpers
Exhaust System
Footrests
Front Fender
Meter Housing
Rear Fender
Seat

Fuel System
Carburetor Assembly
Carburetor Disassembly
Airbox
Carburetor Installation
Carburetor Removal
Fuel Pump
Fuel Tank
Fuel Valve

Engine
Rocker Arms
Camshaft
Cylinder Head
Valves
Cylinder and Piston
Recoil Starter
Stator Side Engine Components
Crankcase
Crankcase Bearings
Oil Pump
Crankshaft
Engine Installation
Engine Removal

Cooling System
Coolant
Radiator
Thermostat
Water Pump

Transmission
Gearshift
PVT Belt
PVT Case
PVT Drive Clutch
PVT Driven Clutch
PVT Inspection
PVT Installation
PVT Removal
Transmission Assembly
Transmission Disassembly
Transmission Removal
Transmission Shafts

Final Drive
Drive Shaft
Front Gearcase
Front Gearcase Inspection
Prop Shaft

Brake System
Aux Master Cylinder
Brake Pedal
Front Brake Cable
Front Brake Calipers
Front Master Cylinder
Rear Brake Caliper

Front Suspension
A-arms
Front Struts

Rear Suspension
Installation
Removal

Steering
Handlebar
Steering Shaft
Tie Rods

Wheels
Wheels and Hubs

Electrical Systems
Battery
Charging System
Diagnostic Mode
Electric Start System
Ignition System
Lights
Meter
Power Box
Speed Sensor
Starter Motor
Switches
Wiring Diagrams