Engine Fuel Systems Body / Suspension: General Maintenance
Engine Fuel Systems Body / Suspension: General Maintenance
Engine Fuel Systems Body / Suspension: General Maintenance
MAINTENANCE 2
ENGINE 3
FUEL SYSTEMS 4
BODY / SUSPENSION 5
FINAL DRIVE 7
TRANSMISSION 8
BRAKES 9
ELECTRICAL 10
A 12 MN 50 AX
Powertrain
Check Digit
Plant No
Individual Serial Number
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Owner's Parts
Year Model Model No.
Manual PN Manual PN
Sportsman Touring 500
2012 A12DH50AX, AZ 9923410 9923411
H.O.
Sportsman Touring 500
2012 H.O. A12DH50FX 9923438 9923413
International
2012 Sportsman 400 H.O. A12MH46AX, AZ 9923420 9923421
2012 Sportsman 500 H.O. A12MH50AD, AQ, AX, AZ, 9923420 9923422
Sportsman Forest 500
2012 A12MH50FF 9923423 9923424
International
Sportsman Forest Tractor
2012 A12MN50ET 9923430 9923431
500 EFI International
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A12MN50ET Clutching
Shift Drive Clutch
Altitude
Weight Spring
0-1800 10 WHF Green / Blue
(0-6000) (5632283) (7041157)
Meters
(Feet) 1800-3700 10 RH Green / Blue
(6000-
(5630709 (7041157)
12000)
MISC. NUMBERS/CHARTS
Conversion Table
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Grade
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Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch
replacement is required.
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SPECIAL TOOLS
SPX Corporation - 1-800-328-6657 or http://polaris.spx.com
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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.
WARNING
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.
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2871329 Dielectric Grease (Nyogel™) • Engine coolant - check for proper level at the
recovery bottle
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
1 2
5
4
6
3A 3B
7
* 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).
(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.
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Drain Plug
Fill Plug
Specified Lubricant:
Demand Drive PLUS Hub Fluid
Left Side View
Gearcase Capacity: 8.97oz. (265 ml.)
The transmission lubricant level should be checked and 1. Remove transmission drain plug to drain the oil.
changed in accordance with the maintenance schedule. Discard used oil properly.
NOTE: The check/fill plug is a 3/16” hex.
• 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.
DRAIN PLUG
=T
Transmission Check/Fill Plug Torque:
14 ft.lbs. (19 Nm)
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The Active Descent Control reservoir is located by the 8. Continue steps 6-8 on both sides in sequence until
radiator fill cap under the storage box access panel. clean fluid is seen when bleeding occurs.
Check the level and verify it is between the MAX and MIN
lines, Add only Polaris ADC fluid when required.
9. Re-torque both bleeder valves to specification and
reinstall cover caps.
2
=T
Bleeder Valve Torque:
80 in. lbs. (9 Nm)
6
5
4
ETC Cover
Removal Sequence
III. 1
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= In. / mm.
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Antifreeze Hydrometer
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Recovery Bottle 2
RECOMMENDED COOLANT
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.
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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.
A
Proper Filter Placement Main Filter
Pre-Filter
Gasket Front
Main Element
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.
Carb Boot
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.
Recoil Housing
Sediment Tube
Drain Plug
Recoil Drain
NOTE: The sediment tube will require more frequent
service if the vehicle is operated in wet conditions or at • Drain the housing periodically to remove
high throttle openings for extended periods. moisture.(If Equipped)
Breather Filter Inspection • Drain the recoil housing after operating the ATV in
very wet conditions. This should also be done
Four-cycle ATV engines are equipped with a breather before storing the ATV. The drain screw is located
filter. The in-line filter is similar in appearance to a fuel filter, at the bottom of the recoil housing. Remove the
and is visible on the left side of the engine. screw with a 10 mm wrench. Reinstall screw once
In-line breather filters can be installed in either housing has been drained.
direction.
• 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.
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Reference mark
=T
Oil Tank Drain Plug Torque: Oil Filter
14 ft. lbs. (19 Nm)
14. Install oil hose (E) on fitting (C) and re-install clamp
(D).
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CAUTION
(A)
Sprocket alignment pin facing up
Crankshaft-to-Camshaft Centerline
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Chalk Line
Measurement
“A” Measurement “B”
= In. / mm.
Check for Loose Wheel or Hub
Wheel Toe-Out:
• Refer to the Body/Steering Chapter 5 or Final (A) - (B) = 0 to 1/16" (0 to 1.6mm)
Drive Chapter 7 for service procedures.
• Hold tie rod end to keep it from rotating. 1. Remove the clean out plugs located on the bottom of
the muffler.
• Loosen jam nuts at both end of the tie rod.
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
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Sight Glass
1 ft.
Auxiliary Brake
= In. / mm.
1. Support the rear wheels off the ground.
Brake Pad Service Limit: 2. While turning the rear wheels by hand, apply the
.180" (4.6 mm) 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.
Hose/Fitting Inspection
Auxiliary Foot Brake Pedal
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks.Tighten any loose Full Height Full
fittings and replace any worn or damaged parts. Engagement
Floor
Board Surface
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1/8, to 1/4, 1” or
50 lbs greater
Free Play
Foot Brake Freeplay: Check all front suspension components for wear or
1/8 - 1/4" (3.2 - 6.35 mm) damage.
Inspect front strut cartridges for leakage.
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any parts CV Shaft Boot Inspection
as needed.
Bleeding: Inspect the CV shaft boots in the front and rear of the ATV
for damage, tears, wear, or leaking grease. If the rubber
If free play is correct and brake pedal travel is still boot exhibits any of these symptoms, replace the boot.
excessive, air may be trapped somewhere in the system. Refer to Chapter 7 for CV boot replacement.
Bleed the hydraulic auxiliary brake system in a
conventional manner, following the procedure outlined in
Brake Chapter 9.
Inspect Boots
WARNING
Item Specification
Steel - Front Wheel Nuts 27 Ft. Lbs. (37 Nm)
Steel - Rear Wheel Nuts 27 Ft. Lbs. (37Nm)
Aluminum 30 ft. lbs. + 1/4 Turn
Front Wheel Nuts (41 Nm + 1/4 Turn)
Aluminum 30 ft. lbs. + 1/4 Turn
Align clamp
edge with Rear Wheel Nuts (41 Nm + 1/4 Turn)
knurl Front Hub Retaining Nut 60 ft.lbs. (81 Nm)
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm)
Align throttle control assembly clamp with knurl on
handlebar.
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CAUTION
Tire Pressure
CAUTION
Tread
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.
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
WARNING the main bore through the pilot outlet.
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2
FRONT
Pilot Screw Location (Engine)
Pilot Screw
Idle Screw
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Drain tube
attached
here
Drain Screw
Fuel Valve
Maintenance Schedule
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Boring Limit
Limit .0024" (0.060 mm)
.020” (.5 mm)
3
Std 3.6204-3.6215" (91.970-91.985 mm)
Outer diameter .0098" (.25 mm) OS 3.6304-3.6310" (92.21-92.23 mm)
Piston
.0197" (.50 mm) OS 3.6403-3.6407" (92.46-92.47 mm)
Standard inner diameter of piston pin bore .9055-.9057" (23.0-23.006 mm)
Outer diameter .9053-.9055” (22.994-23.0 mm)
Standard clearance - piston pin to pin bore .0002- .0003” (.004- .008 mm)
Piston Pin
Piston Pin must be a push (by hand) fit at 68o
Degree of fit
F (20o C)
Std .0079-.0138" (.20-.36 mm)
Top ring
Limit .039" (1.0 mm)
Second Std .0079-.0138" (.20-.36 mm)
Piston Ring Piston Ring Installed gap
ring Limit .039" (1.0 mm)
Std .0079-.0276" (.20-.70 mm)
Oil ring
Limit .059" (1.5 mm)
Std .0016-.0031" (.040-.080 mm)
Top ring
Standard clearance - Limit .0059" (.15 mm)
Piston Ring
piston ring to ring groove Second Std .0012-.0028" (.030-.070 mm)
ring Limit .0059" (.15 mm)
Connecting rod small end ID .9058 - .9063” (23.007 - 23.020 mm)
Std .0003-.0010" (.007-.026 mm)
Connecting rod small end radial clearance
Limit .0020" (.05 mm)
Connecting Rod Std .0039-.0256" (.1-.65 mm)
Connecting rod big end side clearance
Limit .0315" (.80 mm)
Std .0004-.0015" (.011-.038 mm)
Connecting rod big end radial clearance
Limit .0020" (.05 mm)
Crankshaft Crankshaft runout limit .0024" (.06 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side.
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Surface warpage limit (mating with cylinder head) .0020” (0.05 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side.
CAUTION
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3
Cylinder
Cylinder
Head
WARNING
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.
• Cylinder WARNING
• Water Pump / Water Pump Mechanical Seal* 2. Thoroughly clean the engine and chassis.
The following components require engine removal for 3. Remove the following parts as required.
service:
• Seat
• Oil pump / Oil Pump Drive Gear
• Left and Right Side Covers (Refer to Chapter 5)
• Counterbalance Shaft or Bearing(s) • Fuel Tank Cover / Front Cab (Refer to Chapter 5)
• Connecting Rod • Fuel Tank (Refer to Chapter 4)
• Crankshaft 4. Drain the engine oil and engine coolant (see Chapter
2).
• Crankshaft Main Bearings
NOTE: Drain and dispose of the fluids properly.
• Crankcase
5. Remove the spark plug high tension lead.
*It may be necessary to loosen engine mounts and move
engine slightly to access water pump. Use the Water 6. Remove engine to chassis ground cable located at the
Pump Mechanical Seal Puller (PN 2872105) to replace starter motor mounting fastener.
mechanical seal with engine in frame.
7. Remove the red battery cable from the starter motor.
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Fuel Injector
MAP 3
TPS
11. Remove the outer clutch cover with PVT outlet duct,
drive belt, drive clutch, driven clutch and inner clutch 21. Remove the oil lines and breather line from the engine
cover (see Chapter 6). crankcase.
After the engine is installed in the frame, review this 4 Cycle Engine Break-In Period is defined as the first 10
checklist and perform all steps that apply. hours of engine operation or 2 full tanks of fuel.
General Items 1. Use only Polaris Premium 4 All Season synthetic oil,
1. Install previously removed components using new or API certified “SH” oil.Never substitute or mix oil
gaskets, seals, and fasteners where applicable. brands. Serious engine damage can result.
2. Perform regular checks on fluid levels, controls, and 2. Use fuel with a minimum octane of 87 (R+M)/2
all important areas on the vehicle as outlined in the method.
daily pre-ride inspection checklist (refer to Chapter 2 3. Change break-in oil and filter at 20 hours or 500 miles,
or the Owner’s Safety and Maintenance Manual). whichever comes first.
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CAUTION
of the intake and exhaust ports.
3
Cleaning the Cylinder After Honing
For oversize honing, always wet hone using honing oil
and a coarse roughing stone. Measure the piston (see It is very important that the cylinder be thoroughly cleaned
piston measurement) and rough hone to the size of the after honing to remove all grit material. Wash the cylinder
piston. Always leave .002 - .003" (.05 - .07 mm) for finish in a solvent, then in hot, soapy water. Pay close attention
honing. Refer to piston-to-cylinder clearance to areas where the cylinder sleeve meets the aluminum
specifications before honing. Complete the sizing with casting (transfer port area). Use electrical contact cleaner
fine grit stones to provide the proper cross-hatch finish if necessary to clean these areas. Rinse thoroughly, dry
and required piston clearance. with compressed air, and oil the bore immediately with
Polaris 4 Cycle Lubricant.
A A
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Internal passage to
camshaft (front left
head bolt)
Vent Hose
Oil Filter
From filter to
crankshaft
Crankcase Sprocket
Chain Room Chain Small End
Oil Gallery Bearing
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Crankcase Cylinder/
Cylinder Head
Crankshaft
Valvetrain
and Piston
1. Remove ignition timing inspection plug from recoil NOTE: The cam lobe should be pointing down and
housing. valves should have clearance at this point.
Rotation
Advance Marks
To position crankshaft at Top Dead Center (TDC) on 5. Remove cam chain tensioner plug, sealing washer,
compression stroke: and spring. CAUTION: The plug is under spring
tension. Maintain inward pressure while removing.
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close. 6. Remove the two 6x25 mm cam chain tensioner flange
bolts.
3. Continue to rotate engine slowly, watching camshaft
sprocket marks and the mark in the timing inspection 7. Tap lightly on tensioner body with a soft face hammer
hole. and remove tensioner.
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Sprocket teeth
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Stop Pin
3
Decompressor Ball Spring in relaxed position
Retainer Sleeve
Journal
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15. Insert valve into guide and tap valve lightly into place
a few times.
• If the seat is too narrow, widen using the 45o cutter 20. Rotate the valve rapidly back and forth until the cut
and re-check contact point on the valve face and sounds smooth. Lift the valve slightly off of the seat,
seat width after each cut. 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).
Valve Seat Width:
21. Clean cylinder head, valves, and camshaft oil supply
Intake Std: .028” (.7 mm) passage (A) thoroughly.
Limit: .055” (1.4 mm) A
Seat
Width
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.
Bottom - 60o or 75o Seat - 45o or 46o 23. Spray electrical contact cleaner into oil passage and
dry using compressed air.
Top -30o
o
or 31
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NOTE: Assemble the valves one at a time to 8. When all valves are installed, tap lightly with soft faced
maintain proper order hammer on the end of the valves to seat the split
keepers.
1. Install new valve seals on valve guides.
Valve Sealing Test 3
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.
2. Apply engine oil to valve guides and seats. NOTE: The exhaust valves share a common rocker
arm, and must be adjusted using two feeler gauges.
3. Coat valve stem with molybdenum disulfide grease.
1. Insert .006” feeler gauge(s) between end of the valve
4. Install valve carefully with a rotating motion to avoid stem and adjuster screw(s).
damaging valve seal.
5. Dip valve spring and retainer in clean engine oil and
install spring with closely spaced coils toward the
cylinder head.
VALVE CLEARANCE
.006” (.15 mm)
2. Loosen all four oil pipe banjo bolts and then remove
the bolts and eight sealing washers. Remove the
pipes.
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(EH500PLE 498cc )
3.6221 - 3.6228” (92.00 - 92.012 mm)
(EH46PLE 455cc Carbureted)
3.4606-3.4614" (87.90-87.92 mm)
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
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Piston
40 mm
Piston Pin Bore
EH46PLE (455cc)
Std: 3.4594-3.4600” (87.870-87.885 mm)
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Feeler Gauge
Cylinder
Feeler Gauge 25-50 mm 3
Piston Ring-to-Groove Clearance
Piston ring
Top Ring Std: .0016-.0031" (.040-.080 mm)
Limit: .0059" (15 mm) Piston Ring Installed Gap
Second Ring Std: .0012-.0028" (.030-.070 mm) Top Ring
Limit: .0059" (15 mm) Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Starter Drive Removal / Inspection 6. Inspect gear teeth on starter drive. Replace starter
drive if gear teeth are cracked, worn, or broken.
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. 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).
3. Inspect the thrust washer for wear or damage and
replace if necessary.
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.
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A CAUTION
D B
C
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.
Crankcase Separation
2. Remove (2) bolts holding pump drive gear (C).
1. Remove flange bolts (10) from magneto side
crankcase evenly in a criss-cross pattern. 3. Inspect drive gear teeth for cracks, damage or
excessive wear.
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3
6. Remove the three screws and strainer screen from
pump.
Pump End Clearance:
7. Clean screen thoroughly.
Std: .001-.003 (.0254-.0762 mm)
8. Remove pump body screw and feed chamber cover.
Wear Limit: .004 (.1016 mm)
4. Install outer feed rotor and inner feed rotor drive pin.
6. Tighten screw securely. 3. Turn the shaft until balancer counter weights clear the
crankshaft and remove the balancer shaft from the
7. Install screen on pump body. crankcase.
8. Install oil pump on crankcase and torque bolts to 6 ft.
lbs. (8 Nm).
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1. Remove the shim washer (C) from the crankshaft. Big End Radial Clearance:
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Total Case Width______________________ 3. Measure the distance from the Mag crankcase mating
surface to the balance shaft bearing using a dial
7. Measure the width of the crankshaft at the bearing caliper and a straight edge. Subtract the thickness of
seats with a micrometer or dial caliper and record. the straightedge and record.
Crankshaft Width______________________
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NOTE: Do not use gasket sealer on the pump mating (PN 2871557)
surfaces.
NOTE: After engine is assembled and the vehicle is Water Pump Mechanical Seal Installation
prepared for field operation, oil pump MUST be
primed. Follow oil pump priming procedure. 1. Clean the seal cavity to remove all traces of old
sealer.
Oil Pump Bolt Torque: 2. Place a new mechanical seal in the seal drive collar,
and install on the pump shaft.
6. ft. lbs. (8 Nm)
3. Screw the guide onto the end of the pump shaft.
4. Install the washer and nut and tighten to draw seal into
6. Align the drive gear with the drive pin on the pump
place until fully seated.
shaft and install the gear. Be sure the gear is fully
seated and properly engaged. 5. Remove the guide adaptor using the additional nut as
a jam nut if necessary.
7. Install the proper shim washer on the pump shaft.
Crankcase Assembly
1. Apply Crankcase Sealant (PN 2871557) to the
crankcase mating surfaces. Be sure the alignment
pins are in place.
2. Set the crankcase in position carefully to avoid
damaging the pump shaft seal and install the magneto
end crankshaft installation tool (follow instructions
provided with the Crankshaft/Water Pump Installation
Kit (PN 2871283). Draw the crankcase halves
together by tightening the nut on the tool and tapping
lightly in the pump shaft area with a soft faced hammer
to maintain alignment. Continually check alignment of
the cases during installation, closing the gap equally
until the surfaces are tightly seated.
3. Remove the tool.
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CAUTION
4. Ensure that the split between the puller legs is fully
supported by the main body of the tool.
Improper or careless use of this tool or procedure
can result in a bent water pump shaft. Pump 5. Tighten the hex socket screws on the puller legs
shaft replacement requires engine removal and sufficiently so the lip of the puller legs will grasp the
crankcase separation. Use caution while mechanical seal.
performing this procedure. Make sure that the
puller is parallel to the shaft at all times. Hex Socket Screws
Do not place side loads on the water pump shaft
or strike the puller or shaft in any way.
Puller Legs
1. After the coolant has been drained, remove the water
pump cover, impeller and the sealing washer.
Sealing Washer
Sealing Washer Lip must grasp inside
(Copper or Aluminium) of mechanical seal
Coolant Drain
Bolt 6. Turn the puller T-Handle clockwise until it contacts the
Oil water pump shaft. Continue rotating until the
Seal remaining portion of mechanical seal has been
removed from the cases. Pump shaft oil seal can also
Impeller be replaced at this time if necessary.
Mechanical Seal
2. Slide the main puller body over the outer portion of the
mechanical seal as shown below and turn T-Handle
clockwise until it contacts water pump shaft. Continue
rotating until outer portion of mechanical seal is
separated from the metal seal body.
T-Handle
C
Tighten
Slotted Nut Torque: 3. Install the bottom rail with the gap at least 30o from the
35-51 ft. lbs. (4.71-6.86 kg-m) end of the expander on the side opposite the top rail
gap.
4. Install the second ring with the “R” mark facing up.
Tensioner Blade Installation
Position the end gap toward the rear (intake) side of
1. Install the tensioner blade and tighten the mounting the piston.
bolt to specified torque.
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Second
Mark-up
6. Install the other circlip with the gap facing up or down
6. Check to make sure the rings rotate freely in the and tang outward. (See Caution with Step 3 above).
groove when compressed. Push the piston pin in both directions to make sure the
clips are properly seated in the groove.
Piston Installation
Cylinder Installation
1. Clean the gasket surfaces on the cylinder and
crankcase. Remove all traces of old gasket material. 1. Place the dowel pins in the crankcase and install a
new cylinder base gasket.
2. Make sure the cylinder mounting bolt holes are clean
and free of debris. 2. Position the Piston Support Block (PN 2870390) (A)
beneath the piston skirt to support the piston during
3. Install a new circlip on one side of the piston with the cylinder installation.
end gap facing up or down, and tang outward.
Tang Outward A
8. Install all four bolts finger tight. Rotate the engine and
position the piston at BDC.
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Guide in
recess
3
3. Disconnect the wire from the cam chain and rotate the
engine to align the single (TDC ) timing mark (Top
Dead Center) on the flywheel with the notch in the
timing inspection window. Be sure to use the single
TDC mark when installing the cam. Do not use the
advance marks.
Single (TDC)
Mark Aligned
CAUTION
Camshaft Timing
1. Apply Premium Starter Drive Grease (PN 2871460)
to the camshaft main journals and cam lobes.
Lubricate automatic compression release
mechanism with clean engine oil.
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Rotation
Do Not Use
Advance Marks
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Thermostat Installation
Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt hole as 3
shown.
2. Install and tighten rocker arm shaft locating bolt. Oil Pipes
3. Apply starter drive grease to the cam lobes and cam Install the oil pipes with new sealing washers. Tighten all
follower surfaces. bolts evenly to specified torque.
6. Apply a light film of engine oil to the threads of the bolts Oil Pump Priming Procedure
and tighten evenly.
NOTE: The oil pump priming procedure must be
performed whenever the oil hose connection
Rocker Shaft Support Tower Bolt Torque: between the oil tank and pump inlet has been
9 ft. lbs. (12 Nm) disconnected. Refer to the procedure in Chapter 2.
Recoil Disassembly/Inspection
NOTE: 2009 models are not equipped with a recoil
as standard equipment. This section intended for
reference.
CAUTION
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Recoil Assembly
CAUTION 5. Install reel into housing making sure the spring drive
tab on the reel engages the spring and the reel is fully
seated in the housing.
Be sure to wear a face shield and eye protection
6. Apply downward pressure on the reel and rotate
when performing this procedure.
counterclockwise approximately 6-7 turns to pre-wind
the spring. Continue rotating counterclockwise until
rope on outer edge aligns with rope guide bushing.
7. Release rope from notch and allow reel to rewind
completely. If more pre-wind is required, place rope in
notch and add additional turns of pre-wind.
8. Install ratchet pawl and return spring, with long leg of
spring engaged in reel.
9. Reinstall friction plate.
NOTE: The friction plate must be positioned with both
end tabs of the friction spring opposite the ratchet pawl.
10. Torque friction plate retaining bolt to 5-6 ft. lbs. (7-9
Nm).
11. Reinstall recoil housing using a new gasket. Seal
stator wire harness grommet with RTV silicone.
To install a new spring: 12. Torque fasteners to specification.
1. Place spring in housing with the end positioned so the 13. See “Specifications” in the beginning of this chapter.
spring spirals inward in a counterclockwise direction.
See photo at right.
• Dead battery
Spark Plug Fouling
• Starter motor does not turn
• Spark plug cap loose or faulty
• Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Restricted carburetor pilot system
• Incorrect spark plug heat range or gap
• Carburetor misadjusted
• Carburetor inlet needle and seat worn
• Jet needle and/or needle jet worn or improperly • Choke not adjusted properly
adjusted
• Low compression
• Excessive carburetor vibration (loose or missing
needle jet locating pins) • Crankcase breather restricted
• Loose jets in carburetor or calibration incorrect for Engine Idles But Will Not Rev Up
altitude/temperature
• Spark plug fouled/weak spark
• Incorrect float level setting
• Broken throttle cable
• PVT system calibrated incorrectly or components
worn or mis-adjusted • Obstruction in air intake
• Fuel quality poor (old) or octane too high • Air box removed (reinstall all intake components)
• Low compression • Incorrect or restricted carburetor jetting
• Restricted exhaust
• ETC switch limiting speed
• Weak ignition (loose coil ground, faulty coil, stator,
or ETC switch) • Reverse speed limiter limiting speed
• No fuel
• Engine flooded
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• Cylinder or piston worn • Cooling fan inoperative or turning too slowly (perform
current draw test)
• Piston rings worn, leaking, broken, or sticking
• Ignition timing misadjusted
• Bent valve or stuck valve
• Low oil level
• Valve spring broken or weak
• Spark plug incorrect heat range
• Valve not seating properly (bent or carbon accumulated
on sealing surface) • Faulty hot light circuit
NOTES
3.60
4.1
4.2
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A
G
H
4
C
N
M
P L
D
J
E
F
G Cover
H Spring
A D
B F
C
E
J
K
F Spring
H Floats
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Atmospheric
Air inlet
Pilot (Idle Pilot Jet/ Primarily Mainly idle
System) Passage-ways, supplies fuel at to 1/4
Pilot–Mixture idle and low throttle
Vacuum
Screw with throttle positions Minimal Slide
Spring Washer effect after
Throttle Plate
and Sealing O– 1/2 throttle
Ring, By-pass
Ports (Behind
Venturi
Throttle Plate),
Pilot Air Jet, Pilot
Outlet, Throttle
Plate
Main Main Jet, Main Supplies fuel at 1/4 to full
System Air Jet, Main Air mid–range and throttle
= Air Flow = Low pressure
Passage, high throttle
Needle Jet, Jet settings.
Needle, Vacuum When the throttle plate is opened and engine speed
Slide, Throttle begins to increase, the pressure in the venturi (and
Plate therefore in the chamber above the diaphragm) becomes
significantly lower than atmospheric. Atmospheric
pressure in the chamber below the diaphragm forces the
diaphragm upward, raising the slide against spring
pressure.
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7 6
2
3
Fuel is drawn into the starter circuit from the float chamber
(2) through the starter jet (3). Starter jet meters this fuel,
which then flows into starter pipe (4) and mixes with the air
(7) coming from the float chamber. The mixture, rich in fuel
content, reaches starter plunger and mixes again with the
air coming through a passage (8) extending from
underneath the diaphragm. The rich fuel/air mixture for
Note: Diagrams are for explanation of theory only, and are not true starting is discharged through starter outlet (6) in the main
representations of Mikini BST carburetor. bore.
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1
1
6 2
7
7
5
A
2 6
3
5 3
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Inlet
Pipe
3
1
4 2
Brass Plug Removed
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Leaner
Position#
15 50 75 100%
Richer
Throttle Valve Opening
Needle Jet
Main Jet
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O-Ring
Washer
Spring
Pilot Screw
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Needle Jet
Jet Needle
Carburetor Cleaning
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FRONT
(Engine)
Pilot Screw
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PFA Nut
Carburetor Mounting
70 ft. lbs (95 Nm)
PFA Gasket
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Impulse Hose
4. Apply 5 inches (Hg) vacuum to the pump fitting. The 3. Move the seal out of the sealing channel and pull up
diaphragm should hold vacuum indefinitely. on the front of the access cover. Remove the access
cover.
If fuel is present in the impulse line or vacuum chamber of
the pump, the diaphragm is ruptured. The pump must be
replaced.
Typical Filter
Location
PFA NUT
70 ± 5 ft. lbs.
(95 ± 7 Nm)
PFA Gasket
Clean Area
Around PFA Nut
WARNING
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PU-50326
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14. Install the sending unit into fuel tank, hold float arm to
the sending unit body and tilt assembly to ensure float
arm does not get caught or bent during installation.
15. Gently push down on sending unit flange ensuring
flange is centered.
CAUTION
PU-50326
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Installed In Locating
Feature of CVT Outlet
Duct
Under Foam
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• C. Tubing
• E. Catalyst
The emissions system utilizes an air valve filter (A), one-way air valve system (B), and vacuum to help reduce emissions.
The air valve assembly (B) contains a vacuum shutoff. When engine RPM drops quickly or is at high RPM, the air valve
closes. During idle through mid-range RPM the air valve is open and air is drawn into the from the PVT intake duct.
The air valve assembly (B) opens and closes based on the vacuum pressure connected to the air duct.
The exhaust pipe creates a vacuum after each engine exhaust pulse. The air valve (B) opens and closes based on this
engine pulse. Fresh air then travels through the air injection tubes (C and D) and into the exhaust. This air (oxygen) enters
the exhaust pipe and mixes with the exhaust gases from the engine, reducing emissions. The air and exhaust gas mixture
then passes through the silencer (E), which contains a catalyst. This catalyst also reduces emissions by interacting with
the exhaust as it passes through the silencer. NOTE: No maintenance or service of the catalyst is required.
E
A
D C
Air Flow
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Symptoms: Hard start or no start, bog, backfire, popping • Sticky vacuum slide
through intake / exhaust, hesitation, detonation, low power, spark
• Throttle cable sticking, improperly adjusted, routed
plug erosion, engine runs hot, surging, high idle, idle speed incorrectly
erratic.
• Choke cable sticking, improperly adjusted, routed
• No fuel in tank incorrectly
• Loose jets
NOTES
4.24
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PU-47469
PU-47468
PU-47470
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The speed control system utilizes the ECU (A), Speed Sensor (B), Air Control Body (C), Solenoid Valve (D), and engine
vacuum from the throttle body to operate. At closed throttle, the solenoid valve (D) is remains normally closed and the 4
slide valve (E) in the air control body is closed. As the throttle opens and engine RPM increases, the increase in vacuum
opens the slide valve (E), allowing more air to be drawn into the engine. The speed sensor signal (B) is monitored by
the ECU. When the speed sensor signal rises over 40 Kph (25 Mph), the ECU triggers the solenoid valve (D) to open,
allowing atmospheric pressure on top of the slide diaphragm (F). This drops the slide valve (E) down to limit the amount
of air entering the engine. Once the vehicle speed drops below 37-40 Kph (23-25 Mph), the solenoid valve (D) closes
and the operation repeats. Should the vehicle speed reach 67 Kph (42 Mph), the ‘check engine’ light will illuminate on
the LCD gauge to indicate there is a problem with the system.
E F
Carb Adapter
D E
A
F
C
B C
R
AI
D
Cylinder Head
LH Rear Brake
AIR
Body
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• For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Polaris Diagnostic
Software (dealer only), or limited testing may be done manually using the procedures provided.
• 80% of all EFI problems are caused by wiring harness connections. Follow a common sense approach when
diagnosing a potential EFI issue:
1. Disconnect the harness at the suspected sensor connector.
2. Inspect the connector ends for damage or contamination. If damaged, repair; if contaminated, clean. Reconnect and
check function.
3. If the problem persists, perform a sensor bench test according to the specific sensor requirements.
4. If the sensor bench tests pass, disconnect the connector at the ECU and perform a continuity check between the sensor
connector and the appropriate pin at the ECU connector (all connections for that sensor). Wiring resistance should be less
than five (5) ohms.
5. If the resistance is high (or open), a wiring harness inspection is dictated (including a thorough inspection of the ECU
connector for contamination or damage).
6. If the sensor passes and the wiring passes inspection, and reconnecting the ECU does not resolve the issue, then at that
point a known-good ECU (from another 500 EFI ATV) could be connected and tested for problem resolution.
• For the purpose of troubleshooting difficult running issues, a known-good ECU from a same-model Polaris 500 ATV EFI
system may be used without damaging system or engine components.
• Do not use dielectric grease on sealed connectors (connectors with a rubber grommet), as it may displace the rubber seal
and allow contaminants to enter the connector.
• Never attempt to service any fuel system component while engine is running or ignition switch is turned to "on".
• USE CARE when removing or installing the ECU connector, as well as all other harness connections on the ATV.
Dirt, even in small quantities, can cause significant problems. Clean connectors thoroughly before opening to prevent dirt
from entering. Properly connect and disconnect the ECU harness to minimize damage to the connector pins and locking
mechanism.
• Do not use compressed air if the EFI system is open. Cover any parts removed and wrap any open joints with plastic if they
will remain open for any length of time. New parts should be removed from their protective packaging just prior to installation.
• Although every precaution has been taken to prevent water intrusion failure, avoid direct water or spray contact with system
components.
• Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the
ignition "on." This can send a damaging voltage spike through the ECU.
• Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal.
• Never start the engine when the cables are loose or poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Never use a quick-start battery charger to start the engine.
• Always unplug ECU from the wire harness before performing any welding on the ATV.
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7
2
4
9
12 11 6
10
5. Throttle Body
- Located in between the engine and the airbox.
6. Idle Air Control (IAC)
- Located on the throttle body
2. Fuse Panel
- Located under the front access cover. 7. Throttle Position Sensor (TPS)
- Located on the throttle body.
1
2 4&7
6
10 11
9 & 10
7 3 5
2 4&7
9 & 10
3
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7 2 4&7
6 10
9
9 & 10
4
3
2 4&
9 & 10
3
13. Engine Coolant Temperature Sensor (ECT)
- Located on the LH side of the cylinder head.
11
Fuel Flow
Fuel Tank
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1. Thoroughly clean the connector. Place a shop towel The ECU compares the input signals to the programmed
around the fuel line to catch any dripping fuel. maps in its memory and determines the appropriate fuel
Squeeze the connector tabs together and push the and spark requirements for the immediate operating
locking tab out. conditions. The ECU then sends output signals to set the
2. Pull out on the fuel line for removal. injector duration and ignition timing.
3. To install the line, verify the connector and nipple are
clean and free of debris.
4. Snap the fuel line back over the nipple, verify the
connector tabs snap back into place.
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ECU Replacement
1. Remove the 2 retaining screws holding the ECU.
NOTE: Retain upper-left spacer located behind the
ECU for re-installation.
2. With the ignition turned off, disconnect the wire
harness by pulling the black slider away from the
ECU. Once the slider is fully extended, pull the
connector from the ECU, using great care not to
damage the harness connector or locking
mechanism. NOTE: Should the black slider become
broken, replacement parts are available.
3. To install, reverse the procedures, DO NOT apply
dielectric grease to the connector, as it is a sealed
connector. Install the upper-left retaining screw
spacer and screws. Tighten screws to 10 in. lbs. (1.1
Nm).
CAUTION
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NOTE: If the voltage is below 7Vdc, test the battery, 1. Disconnect the negative battery cable.
ignition switch, wiring harness and ECU. 2. Remove the seat side panels and front cab/fender
assembly. Refer to Chapter 5 for details.
4. If voltage at the plug was good, and there was 3. Remove the clamps on the PVT intake duct and
continuity across the pump terminals, reconnect the
plug to the pump, making sure you have good, clean
remove the PVT duct.
4
connections. Turn on the key switch and listen for the
pump to activate.
NOTE: If the pump starts, repeat steps 1 and 2 to
verify correct pressure.
4. With all the body panels removed from the front of the
ATV and the fuel tank exposed, disconnect the pump
wiring harness.
WARNING
7. Remove the air box cover and remove the two fuel
tank mounting bolts at the rear of the gas tank.
8. Carefully pull the fuel tank out of the frame. Keep the
fuel tank horizontal during removal, this will keep the
fuel in the tank from spilling out the top inlet.
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1. Disconnect battery.
CAUTION
ECU
It is possible for pressurized fuel to be present
when disconnecting the fuel line.
It is recommended to allow the vehicle to sit for
a period of one hour after shutting off the engine
before servicing the fuel pump. This allows the
exhaust to cool and fuel pressure to drop.
5. Disconnect the fuel pump / sending unit connection
and measure the resistance between the Purple and NOTE: A small amount of fuel may come out of the
Brown wires (see chapter 10 for further details). If out fuel line or tank. Properly drain fuel into a suitable
of specification, replace the fuel pump. container.
CAUTION
14. Install fuel pump into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm does
not get caught or bent during installation.
PU-50326
8. Carefully lift the fuel pump out of the fuel tank. As the
fuel pump assembly is being removed, be aware of
float arm and pump pre-filter. Hold the float arm to the
pump body as you lift and tilt the pump to ensure that
the float arm is not bent when removed from the tank. Align
10. Inspect the inside of the fuel tank for debris (may CAUTION
require flashlight and mirror). If debris like mud or sand
is present, fuel tank should be flushed and cleaned out Failure to align the orientation marks may lead
prior to installation of new fuel pump assembly. to interferences with the fuel level float arm
and cause incorrect function.
IMPORTANT: It is recommended to remove the fuel
tank from the vehicle and rinse it with a small amount 17. While maintaining downward pressure, thread new
of clean fuel. Do not use water or any other chemicals PFA nut onto fuel tank and hand tighten. Use care
to remove debris. when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
between fuel pump and fuel tank.
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PFA NUT
70 ft. lbs. (95 Nm)
70 ± 5 ft. lbs. (REPLACE PFA NUT
(95 ± 7 Nm) EACH TIME IT IS LOOSENED
OR REMOVED)
4
Float Arm
PU-50326
=T
Fuel Pump PFA Nut:
70 ± 5 ft. lbs. (95 ± 7 Nm)
PFA Gasket
19. Verify alignment of fuel pump and tank orientation
marks.
23. Test the fuel pump by turning on the key and listening
for the pump to activate. Cycle the key several times
to prime the system. Clean Threads
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The engine speed sensor is essential to engine operation, 1. Disconnect main harness connector from ECU.
constantly monitoring the rotational speed (RPM) of the 2. Connect an ohmmeter between the pin terminals. A
crankshaft. resistance value of 185W ± 20% at room
temperature (20° C, 68° F) should be obtained. If
Interrupt resistance is correct, check the mounting, air gap,
toothed ring gear (damage, runout, etc.), and flywheel
key.
CPS
Crankshaft Position Sensor Resistance:
185 ± 20% @ (20° C , 68° F)
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FIG. 1
4
Map Sensor Test
= In. / mm. MAP sensors are a non-serviceable item. If it is faulty, it
must be replaced. This sensor requires a 5 Vdc input to
CPS Air Gap: operate, therefore the MAP sensor should only be tested
0.4 - 1.2 mm (0.015 - .047 in.) using Polaris Diagnostic Software (dealer only). Refer to
the EFI Diagnostic Software Manual for more information.
IAT Resistance:
2.45±0.24 (New)
2.45±0.36 (Used)
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Using an ohmmeter-
1 2 3
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1.10v
Fig. 2
Engine Coolant Temperature Sensor (ECT) 1. Disconnect sensor from engine harness.
2. Using a wrench, remove and replace the sensor,
applying a light coating of thread sealant to aid
Coolant passes through the cylinder and by the sensor installation.
probe, varying a resistance reading which is relayed to the 3. Torque the sensor to specification.
ECU. This signal is processed by the ECU and compared
to it's programming for determining the fuel and ignition
requirements during operation. The ECU also uses this =T
signal to determine when to activate the fan during
operation. If for any reason the engine temperature sensor ETS Installation Torque:
circuit is interrupted, the fan will default to “ON”. 18.5 ft. lbs. (25 Nm)
4.54 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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FUEL STARVATION / LEAN MIXTURE Symptom: Idle Too High (If greater than 1300 RPM when
engine is warm)
The correct position of the throttle body idle • Throttle stop screw tampering - replace throttle
stop is established and set at the factory. Do not body
loosen the throttle body idle stop or alter the
stop position in any fashion. If the stop is • Throttle cable sticking, improperly adjusted, routed
repositioned, the entire throttle body assembly incorrectly
must be replaced.
• Failed Sensor or disconnected wiring
Symptoms: Hard start or no start, bog, backfire, popping • IAC stuck or inoperative
through intake / exhaust, hesitation, detonation, low
power, spark plug erosion, engine runs hot, surging, high • Intake air leak
idle, idle speed erratic.
Symptom: Idle Too Low (if less than 900 RPM when 4
• No fuel in tank engine is warm)
• Throttle stop screw tampering - replace throttle • Throttle cable incorrectly adjusted
body
• Air Leaks, dirty injector
• Failed Sensor or disconnected wiring
• TPS damaged or adjusted
RICH MIXTURE • Tight valves
Symptoms: Fouls spark plugs, black, sooty exhaust • Belt dragging
smoke, rough idle, poor fuel economy, engine runs rough/
misses, poor performance, bog, engine loads up, backfire. • Dirty air cleaner
• Poor fuel quality (old fuel) • Throttle stop screw tampering - replace throttle
body
• Fouled spark plug
• Failed Sensor or disconnected wiring
• TPS setting incorrect
• Injector failure
EFI DIAGNOSTICS USING ‘BLINK NOTE: To clear codes manually, disconnect the
positive battery lead for 20 seconds.
CODES’
Blink Codes - Operation ON
Any “blink codes” that are stored in the ECU will display,
one at a time, in numerical order. The word ‘WAIT’ will
appear on the LCD display and the Malfunction Indicator
Light (MIL) or Check Engine light will begin to flash. Read
and record the number of flashes of the MIL light. A code
‘12’ indicates the beginning of the diagnostic sequence. A
code ‘61’ will flash after all codes have been transmitted.
Sequence Begin
Trouble Code
Trouble Code
Trouble Code
Sequence End
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The Digital Wrench™ diagnostic software allows the technician to perform the following tests and observations:
• View or clear trouble codes • Perform guided diagnostic procedures
• Analyze real-time engine data • Create customer service account records
• Reflash ECU calibration files • Perform output state control tests (on some
models)
4.58 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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1. Open the Digital Wrench™ software. Locate the NOTE: Only authorized Polaris dealers and
version ID shown on the lower right side of the Digital distributors can access the dealer website.
Wrench™ start-up screen.
1. Log on to www.polarisdealers.com.
Version
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4
5. Select the “Special Tests” icon. 8. Copy (CTRL+C) the Request Code that will be
required on the dealer website in the next step. DO
NOT CLOSE Digital Wrench™ or the Request Code
will be invalid. NOTE: All characters are letters;
there are no numbers in a request code.
“Authorization Key”
Enter the
“Request Code”
Enter the
“Authorization Key”
11. Select the same file type from the list that you selected
previously while in Digital Wrench™. Enter the VIN
along with the customer’s name and address. When
completed, click the Authorize button once to 14. At this point the reflash process will begin. Do not
proceed. touch the vehicle or PC during the process.
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NOTES
4.70
5
REAR RACK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
REAR CAB AND SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
REAR STORAGE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
WINCH AND FRONT BUMPER MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
HEADLIGHT POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
500 EFI TRACTOR SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
SEAT DAMPENER REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
SEAT PIVOT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
500 EFI TRACTOR SEAT ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . 5.17
500 EFI TRACTOR STEERING POST AND LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
HANDLEBAR BLOCK INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
STEERING / A-ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
SPORTSMAN REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
TORSION BAR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
5.2 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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The inside insert (A) should be flush with the top of the
outside insert (B). 5
A
Step 1
2. Grasp the rear of the side panel near the rear cab.
With a firm motion, pull the panel outward to
disengage the side panel from the grommet. Pull the
panel downward and rearward to remove it from the
ATV.
Step 2
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B
18 in. lbs
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A
5
5. Remove the seat and side panels, refer to the “SIDE
PANEL REMOVAL” section.
6. Remove the plastic inserts (D) that secure the front of
the foot wells to the front fender.
D
D
7. Remove the fuel cap and place a clean lint free shop
towel into the tank neck to keep any debris from falling
into the tank.
8. The front fender should now slide back over the fuel
tank and fuel tank neck.
9. Reverse the removal steps for installation. Torque (6)
front fender-to-frame screws to specification.
=T
Fender to Frame Screws
24 in.lbs. (2.7 Nm)
Latch Asm.
Seal
Cable
Hinge
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Front Cover /
Access Panel
Side Cover
Front Cab
Side Cover 5
Splash Guards
MAIN FRAME
T27-1/4-20X1.00 (X4)
5/16-18X1-3/4 (X2)
LH RADIATOR SHIELD
UPPER RADIATOR BRACKET
1/4-20X5/8 (X6)
BUMPER ASM.
#8X1.00 (X4)
5/16-18X3/4 (X2)
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#14X1-3/4 (X2)
5/16-18X3-1/4 (X2)
1/4-20X1-1/2 (X4)
REAR RACK
5/16-18X2-1/2 (X2)
5/16-18X1-3/4 (X4)
5
MAIN FRAME
#10-24X3/4 (X2)
BUMPERS
SPRING
RETAINER BRACKETS
RIVETS
RUBBER MOUNTS
REAR CAB
LH FOOTWELL
1/4-20X1.00 (X8)
RH FOOTWELL
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PANEL FOAM
GASKET
5
DRAIN PLUG DOOR
LATCH
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Worklight Switch
A
Instrument
Cluster F
A
ETC
Brake
G
5
D
C
E
Wheel Speed Sensor - Sportsman
C
Disassembly Assembly
• Remove two side Phillips screws (A) • Install bottom of pod onto handlebar and secure to
brackets
• Remove one rear Phillips screw (B)
• Lift top half of pod • Install key switch, choke cable, and headlight
• Disconnect instrument cluster wire connectors • Connect 12Vdc power outlet (where applicable)
• Disconnect work light switch connector • Connect headlight
• Disconnect 12Vdc power plug (G)
• Connect instrument cluster connectors to
• Disconnect headlight harness instrument cluster
• Remove ignition switch (C) and choke cable (D) • Install top of pod onto bottom half, making sure
• Remove headlight (F) with adjuster interlocking tabs mate properly
• Remove two screws securing bottom half of pod • Install two side Phillips screws
(E)
• Install one rear Phillips screw
Overview
WARNING
The Sportsman 500 EFI Tractor seat assembly consists of
a pivoting seat base holder that combines a hydraulic Spring Under Tension
dampener with spring preload to compensate for rider Use the proper precautions when working with
weight. Adjust the seat spring preload for the comfort of springs. Always relieve spring tension before
a lighter or heavier operator. Reach under the rear rack to disassembly. Wear safety glasses and other
access the adjuster. Tighten the spring for heavier riders. appropriate protection at all times.
Loosen the spring for lighter riders.
The seat dampener is a non-serviceable component. If it
Seat Preload Adjustment
is determined to be faulty, it must be replaced.
Use the following table to determine the best preload
1. IMPORTANT: Remove all spring preload before
measurement for rider weight. Measure preload distance
service.
between the adjuster plate and the lower spring cup.
2. Remove the seat.
Rider Weight Preload Measurement 3. Remove the fasteners and cross bolts from each end
of the dampener assembly.
0 - 39 kg 0 mm 4. Remove the dampener and install a new one.
39 - 94 kg 0-32 mm 5. Install the cross-bolts and fasteners. Torque to
94 + > kg 32-64 mm standard specifications as listed in Chapter 1 of the
Sportsman Service Manual.
Seat Height Adjustment 6. Reinstall seat and adjust spring pre-load to desired
setting.
To raise or lower the seat for operator comfort, reposition
the latching mechanism in one set of the rear seat base Seat Pivot Repair
slots. Verify seat is securely installed before operating.
WARNING
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1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV.
2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV.
3. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation. The pin (A)
and middle hole (B) should face the front of the ATV.
4. Install the pin side bolts first and evenly tighten the bolts down. Evenly torque the 2 front bolts to specification.
=T
Handle Bar Bolt Torque
14 ft.lbs.(19 Nm)
5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification.
NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed.
Steering Post
25-30 ft.lbs.
(35-41 Nm)
A
25 ft.lbs. (35 Nm)
NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the
proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Verify inner rod
ends are placed between the steering post arms.
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1. Elevate and safely support vehicle with weight removed from front wheel(s).
2.
3.
Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly. 5
4. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed.
5. Examine A-arm shaft. Replace if worn. Discard hardware.
6. Insert A-arm shaft into new A-arm.
7. Install CV joint shields.
8. Install new A-arm assembly onto vehicle frame. Torque new bolts to specification.
=T
A-Arm Bolt Torque: 37 ft. lbs. (50 Nm)
WARNING
9. Attach A-arm to hub strut assembly. Tighten ball joint nut to specification. If cotter pin holes are not aligned, tighten
nut slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite
directions around nut.
=T
Ball Joint Nut Torque: 30 ft. lbs. (41 Nm)
WARNING
L
E
B 13. To install a new ball joint, Remove extension cap and
attach puller guide using short bolts provided in the kit.
A 14. Remove extension cap and attach puller guide using
D short bolts provided in the kit.
15. Insert new ball joint (K) into driver (L).
4. Remove cotter pin (A) from ball joint castle nut (B).
16. Slide ball joint/driver assembly into guide.
5. Remove castle nut (B) and separate A-arm (C) from
ball joint stud. 17. Apply heat to ease installation.
6. Remove screws (D) and ball joint retaining plate (E). 18. Drive new joint into strut housing until fully seated.
7. Use the Ball Joint Replacement Tool (PN 2870871), 19. Apply Loctite™ 242 (PN 2871949) to threads of
remove ball joint (F) from strut housing. Refer to retaining plate screws or install new screws with pre-
photos. applied locking agent. Torque screws to specification.
=T
G
H Retaining Screw Torque: 8 ft. lbs. (11 Nm)
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=T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
15 ft. lbs.
(21 Nm)
17 ft. lbs
(23 Nm)
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50 ft. lbs.
(69 Nm)
50 ft. lbs.
(69 Nm)
37 ft. lbs.
(50 Nm)
37 ft. lbs.
(50 Nm)
Stabilizer Bushing
17 ft. lbs.
(23 Nm)
37 ft. lbs.
(50 Nm)
Stabilizer Bar
30 ft. lbs.
(40 Nm)
37 ft. lbs.
(50 Nm)
30 ft. lbs.
(40 Nm)
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WARNING
TOOL DESCRIPTION PART NUMBER
Drive Clutch Puller 2870506 All PVT maintenance or repairs should be
Clutch Holding Wrench 9314177 performed only by a certified Polaris Master
Service Dealer (MSD) technician who has
Clutch Holding Fixture 2871358 received the proper training and understands
Drive Clutch Spider Removal and the procedures outlined in this manual.
2870341
Install Tool Because of the critical nature and precision
Roller Pin Tool 2870910 balance incorporated into the PVT
components, it is absolutely essential that
Clutch Bushing Replacement Tool Kit 2871226 no disassembly or repair be made without
Piston Pin Puller 2870386 factory authorized special tools and
Universal Clutch Compressor Tool PU-50518 service procedures.
Clutch Bushing Replacement Tool Kit 2871025
The Polaris Variable Transmission (PVT) consists of three
Clutch Alignment Tool PA-49011 major assemblies:
Center Distance Tool 2871710
1) The Drive Clutch
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6.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of
drive belt burning.
EBS
One Way Clutch
NON-EBS
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6
B
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=T
Inner Cover Bolt Torque (Rear):
12 ft. lbs. (16.6 Nm)
Driven Clutch Retaining Bolt Torque: 3. To remove drive belt, put transmission in gear, apply
6
17 ft. lbs. (23.5 Nm) brake, pull upward and rearward on belt to open
driven clutch sheaves, pull out and down on belt to slip
Drive Clutch Retaining Bolt Torque: over the driven clutch outer sheave.
47 ft. lbs. (64 Nm)
3. Belts with thin spots, burn marks, etc., should be CLUTCH ALIGNMENT
replaced to eliminate noise, vibration, or erratic PVT
operation. See the Troubleshooting Chart at the end Clutch Alignment Tool Use
of this chapter for possible causes.
Clutch alignment is controlled by the number of washers
that are placed behind the driven clutch on the
Belt Installation
transmission input shaft. Adding washers behind the
1. Loop belt over the drive clutch and over top of the driven clutch will move the drive belt toward the moveable
driven sheave. sheave of the drive clutch. Removing washers from
behind the driven clutch will move the drive belt toward the
stationary sheave of the drive clutch.
3. Loosen the hose clamp and remove the PVT air outlet
duct hose from the outer PVT cover.
PA-49011
3. The belt then should be able to be pushed down into
and between the sheaves.
6.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Stationary
Sheave
Shaft Bearing
Alignment Washers
(.060”) PN: 7556120
Deflection Measurement
See Spec Below
Center
Distance
10.05 in. / 255 mm
6.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Bushing Lock
Washer
Spring
Cover
Bearing
Spider Bolt
Bearing
Non-Braking Flat
Bearing Spacer Washer
Button Cover
Screws
Roller Pin
Button Washers
Nut
6
Bolt
Washers Shift
Weight
6.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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6
Inspect for
excessive wear
WARNING
2870341
2871358-A
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more
brass than Teflon is visible
Clutch Holding Fixture: (PN 2871358-A) on the bushing. Refer to bushing
replacement in this chapter.
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the 3. Inspect all rollers, bushings and roller pins by pulling
spider during assembly. Be sure to note the number a flat metal rod across the roller. Turn roller with your
and thickness of these washers. finger. If you notice resistance, galling, or flat spots,
To maintain proper clutch balance and belt-to-sheave replace rollers, pins and thrust washers in sets of
clearance, be sure to reinstall original quantity and three. Also inspect to see if roller and bushing are
thickness washers separating. Bushing must fit tightly in roller. Use the
Roller Pin Tool (PN 2870910) to replace rollers and
pins. Take care not to damage roller bushing or
bearing surface of the new pin during installation.
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= In. / mm.
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= In. / mm.
Moveable Sheave Bushing Inspection:
Shaft Diameter: Replace the cover bushing if more brass
Standard: 1.3745 - 1.375 than Teflon is visible on the bushing.
Service Limit: 1.3730” Refer to bushing replacement
6. Visually inspect PTFE thrust washer for damage.
in this chapter. 6
Measure the thickness and compare to specification.
Replace if worn or damaged.
= In. / mm.
=T
Spacer washers
Cover Screw Torque:
3. Compress spider buttons for each tower and install 90 in. lbs. (10.4 Nm)
spider, making sure that “X”, or the marks that were
made earlier, on spider aligns with “X”, or the marks
that were made earlier, in moveable sheave.
6.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Roller
Button
One Way Nut
Washer
Clutch Spacer 15-25 in. lbs
(2.75 Nm) 40 ft. lbs.
(54 Nm)
Spring
Spider Pin
Stationary Bearing 190-210 ft. lbs. Moveable
Bolt
Sheave (271 Nm) Sheave
Washer Weight 100 in. lbs
Washer Bolt Cover (11.25 Nm)
Drive Clutch Disassembly 3. Inspect cover bushing (A). The outer cover bushing
is manufactured with a Teflon coating. Wear is
1. Using a permanent marker, mark the cover, spider, determined by the amount of Teflon remaining on the
and moveable and stationary sheaves for reference,
as the cast-in X's may not have been in alignment
bushing.
6
before disassembly. A
Spider Removal
2. Inspect the Teflon coating on the moveable sheave
1. Install clutch in holding fixture and loosen the spider bushing.
(counterclockwise) using Clutch Spider Install Tool
(PN 2870341).
2870341
2871358-A
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WARNING
1
2
= In. / mm.
Shaft Diameter:
Standard: 1.3745 - 1.375 (
Service Limit: 1.3730”
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CAUTION
=T
Spider Torque:
200 ft. lbs. (271 Nm)
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#9
#10
#8
CAUTION
2. Install handle end of the Piston Pin Puller (PN 6. With towers pointing toward the vise, slide sheave
2870386) securely into bench vise and lightly grease onto puller rod.
puller threads.
7. Install removal tool (Item A, B) into center of sheave
with “A side" toward sheave.
Piston Pin Puller (PN 2870386)
NOTE: Use Bushing Tool PA-47336.
3. Remove nut from puller rod and set aside. 8. Install nut (C) onto end of puller rod and hand tighten.
Turn puller barrel to increase tension on sheave if
needed. Using a hand held propane torch, apply heat
Piston Pin Puller around outside of bushing until tiny smoke tailings
(PN 2870386) appear.
Bushing
Piston Pin
Main Adapter Puller
(8)
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4. Insert installation puller tool (Item A/B) with “A” side Cover Bushing Installation
down, into center of bushing.
1. Apply Loctiteä 609 evenly to bushing bore in cover.
NOTE: 700 EFI Clutch - Use Bushing Tool PA-
47336. 2. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
5. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
3. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
6. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed. 4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
7. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is 5. Turn clutch cover counterclockwise on puller rod until
seated. bushing is seated.
8. Remove nut from puller rod and set aside.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
9. Remove sheave from puller.
Adapter Reducer
(9)
Main Piston Pin
Adapter (8) Puller
5. Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
DRIVEN CLUTCH
Button Ramp
Inner Sheave
Stationary Ramp
Clutch Spring
Outer Sheave
Spacer Shims
Moveable Bearing
Clutch Disassembly / Inspection 3. Note the location of the spring and remove helix.
4. Note the location of the spring in the moveable
1. Apply and hold downward pressure on the helix, or
sheave, and remove the spring.
place driven clutch in the Clutch Compression Tool
(PN 8700220).
CAUTION
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Belt deflection
adjustment washers 9. Inspect driven clutch faces for wear or damage.
10. Clean and inspect splines on helix and transmission
input shaft.
6
11. Lube splines with a light film of grease. Do not
lubricate the bushings!
Used to adjust
belt tension. One must
always be installed.
Adapter
Piston Pin Puller Reducer (#9)
(PN 2870386)
CAUTION
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Moveable Spring
Example: Helix Sheave Tension
2 - 1 Heavy
Spring/ 2 - 2
Position 1 - 1
2 - 3 5. While holding downward pressure on helix, wind
1 - 2 moveable sheave counterclockwise approximately 1/
1 - 3 Soft 3 turn (120°).
Driven Spring
Driven Clutch
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6.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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B
10. Pull out the clutch roller pins (J) and rollers (K).
K J
6. Remove the inside spider plate (D) and spider
dampener (E). Inspect the spider dampener (E) for
wear and replace if needed.
D
I 6
11. Press the shaft and bearing out of the outer sheave
using an arbor press.
F G H
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© Copyright 2011 Polaris Sales Inc.
Align X’s
4. Install the roller (A) onto the roller pin (B) on both
sides.
NOTE: Press only on the outer race of the bearing
during installation to prevent from damaging the
bearing.
H
Flat Side Down
10. Install the spider assembly onto the shaft with the
6. Install the spring pins (C) to secure the roller pins. retaining ring on top of the spider. NOTE: Use the
Install until flush with sheave surface. marks previously made to align the skip tooth spider,
or use the “X” on top of the spider and align it with the
C skip tooth on the shaft.
6.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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13. Install the cam (helix) assembly over the shaft. Line
up the “X” on the cam, “X” on spider, and “X” on the
stationary sheave or use the marks previously made
Press down before disassembly. NOTE: If the cam assembly
on spider (helix) is difficult to install, be sure the sheaves are
aligned. To align the sheaves place the clutch
assembly on a flat surface with the cam assembly
(helix) side down. Press down on the moveable
6
sheave belt face with both hands and the helix will
release.
Press Down to Loosen Helix
#2 #3
#5
#9
#10
#8
6.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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6. Install left hand thread nut (C) onto puller rod and hand
tighten against installation tool.
8. Remove nut (C) (left hand thread) from puller rod and
set aside.
-Drive clutch shift weights incorrect for application -Install correct recommended shift weights.
(too light).
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
Engine RPM above
sheaves through entire range to further determine
specified operating
probable cause.
range.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.
-Converter sheaves greasy; belt slipage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch
engagement. -Excessive belt / sheave clearance with new belt. -Perform belt / sheave clearance adjustment with shim
washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
Drive belt turns over -Clutch alignment out of spec. -Adjust clutch alignment.
Belt burnt, thin spots -Dragging brake -Vehicle operated with park brake on. Inspect brake
system.
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement.
6.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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-Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary.
on cover. Seal PVT system ducts.
PVT cover
-Clutches or weight being applied to cover while in -Remove weight. Inform operator.
overheating (melting)
operation.
-High vs. low range. -Instruct operator on guidelines for operation in proper
driving range for different terrain as outlined in Owner’s
Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
Water ingestion -Operator error -Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and Maintenance
Manual.
-Belt worn out -Replace belt.
NOTES
6.46
FT.LBS.
COMPONENT NM PART NUMBER TOOL DESCRIPTION
(IN.LBS.)
7.2 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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CAUTION
2. From the back side, tap on the outer bearing race with
a drift punch in the reliefs as shown.
Remove 4 Bolts
5. Pull the hub and strut assembly out and pull the drive-
shaft out of the gearcase.
7.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
=T
Gearcase Mounting Bolt Torque:
30 ft. lbs. (41 Nm)
7.6 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAUTION
7.8 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Torsion Spring
B H-Spring
A
C B
7.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
C
D
14. Remove the bolts retaining the input shaft cover and
pinion gear assembly.
15. Remove the snap ring retaining the input shaft
assembly. 7
2. Press the pinion shaft seal into the pinion cover, until
the seal is flush with the sealing surface.
=T 8. Install the ring gear and roll cage assembly into the
gearcase housing.
Input Cover Bolt Torque
7-11 ft. lbs.
7.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Engage
Tabs
10. Align the spring retainer dowel pin with the ring gear NOTE: Verify armature plate tabs are in the slots on
dowel pin and install the retainer on top of the torsion the roll cage and are resting in the ring gear grooves.
spring.
13. Install the output hub and cover plate assembly with
a new o-ring (arrow) onto the gearcase.
Align during
installation
7-11 ft.lbs.
=T
Output Cover Bolt Torque
7-11 ft. lbs.
15. Lay the gearcase on the side with the output cover
facing up.
Front Gearcase Coil Resistance:
24 ±10%
7.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Coil
U-Shaped Insert
x4
7.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Armature Plate
Ring Gear
1 15
33 18
26 25 20
28
12
2 6
7
10
27
29
22
19
8 32
5
16
17
4
32 8
13
1 11 32
9 24
31
(9)
3
23
14 21
7.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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ADC Engagement: When the AWD switch is set to ‘4x4/ Hydraulic pressure stops and the pistons release,
ADC’, a 12 Vdc current is present at the input shaft coil (1). disengaging the ADC function. The vehicle returns to rear
Operation is controlled by the ECU grounding and wheel drive until the next deceleration.
5
7
1
2
3
4
7
7
U-Shaped Insert
7.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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=T
Bleeder Valve Torque:
80 in. lbs. (9 Nm)
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C
A
D
2 4
15. Inspect the magnetic coil (1) and bushing in the input
cover plate assembly. Replace the input cover seal.
12. Inspect the armature plate for a consistent wear
pattern. Uneven wear of the armature plate indicates
a warped plate, which may cause intermittent
operation.
7.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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AIR
PA-48542
7.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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2
1
Tool PA-48542
=T
Input Cover Bolt Torque:
7-11 ft. lbs. (9.4-14.9 Nm)
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1
3
2
2 2
11. Install the armature plate. Verify the armature plate 13. Install the remaining output clutch assembly.
tabs align with tab recesses in the roll cage and ring NOTE: Align output hub in the ring gear recesses.
gear. during installation.
=T
Input Cover Bolt Torque:
7-11 ft. lbs. (9.4-14.9 Nm)
2. Using a 3/32 hex wrench, turn the back-lash screw out
15. Install a new passage o-ring (dotted circle) on the 3-4 turns. Re-apply Loctite 262Ô onto the bottom
gearcase and install the piston pump assembly. screw threads.
Torque the screws to specification.
=T
Pump Assembly Screw Torque:
17-23 in. lbs. (1.9-2.5 Nm)
7.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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6. Remove wheel.
9. Remove cotter pin and nut from lower A-arm ball joint.
7.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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=T
Front Hub Retaining Nut Torque:
60 ft. lbs. (91 Nm)
Installation
5. Install brake caliper and tighten bolts to specification.
1. Install new compression ring on drive shaft. Apply an
Refer to Chapter 9.
anti-seize compound to splines. Align splines of drive
shaft with front gearcase and install by lightly tapping
on drive shaft with soft-faced hammer. =T
2. Install drive shaft in strut.
Brake Caliper Fastener Torque:
3. Install lower ball joint, torque nut to specification and
install new cotter pin.
18 ft. lbs. (24 Nm) 7
6. Install wheel and tight wheel nuts to specification.
=T Refer to the beginning of this chapter.
Item Specification
Ball Joint Retaining Nut Torque:
30 ft. lbs. (41 Nm) Steel - Front and Rear
27 ft.lbs. (37 Nm)
Wheel Nuts
4. Install hub and tighten hub nut to specification. Aluminum - Front and Rear 30 ft. lbs. + 1/4 Turn
Wheel Nuts (41 Nm + 1/4 Turn)
Front Hub Retaining Nut 60 ft.lbs. (81 Nm)
Rear Hub Retaining Nut 80 ft.lbs. (108 Nm)
B
C
9. Remove hub.
7.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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2. From the back side, tap on the outer bearing race with
a drift punch in the reliefs as shown or press out using
a hydraulic press.
=T
Lower Control Arm Bolt Torque:
37 ft. lbs. (50 Nm)
CAUTION
7.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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=T
Rear Hub Nut Torque:
80 ft. lbs. (109 Nm)
Removal
1. Remove rear hub. Refer to “REAR HUB REMOVAL”
in this chapter.
2. Remove upper carrier bolt. Tip hub outward and
remove shaft from carrier.
7
=T
Rear Hub Nut Torque:
80 ft. lbs. (109 Nm)
=T
Wheel Nut Torque:
Steel Wheels - 27 ft. lbs. (37 Nm)
Aluminum Wheels - 30 ft. lbs. + 1/4 turn (41 Nm
+ 1/4 turn
7.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Inner CV
Drive Axle Components
Joint Compression Compression
Ring Inner Boot Ring
Outer Boot
Compression
Ring
Outer CV Joint
Clamps
Boot
Outer Clamp 7
NOTE: When replacing a damaged boot, check the 3. Clean the grease from the face of the joint.
grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If 4. Place the drive shaft in a soft-jawed vise.
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only (see illustration).
NOTE: Use only the Constant Velocity Joint grease
supplied with boot service kit. IF CV JOINT WAS
CLEANED, add the recommended amount of grease
to the joint in addition to the grease pack supplied
with boot kit.
7.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in it’s groove
7. Remove the CV boot from the shaft. machined in the shaft.
CAUTION
21. Install and tighten the small clamp on the boot using
the Axle Boot Clamp Tool (8700226 or PU-48951).
15. Use a soft-faced hammer to tap the joint onto the drive
shaft until it locks into place.
7.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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2. Remove the large end of the boot from the plunging IMPORTANT: Tap on inner race only!
joint and slide the boot down the shaft.
6. Make sure the circlip is still on the shaft and not left in
the joint.
Circlip
CAUTION
14. Fully compress the joint and push the drive shaft firmly
into the inner race.
8. Thoroughly clean the joint with an appropriate solvent 15. Align the circlip with the lead-in chamfer.
and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
machined in the shaft.
CAUTION
7.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Wheel Side
Boot Kit
CV Joint
NOTE: If removing rear propshaft, loosening and/or
REAR SHAFT removal of rear gearcase mounting bolts may be
required to gain necessary clearance for propshaft
Spring Ring
removal.
Plunging
Joint
Gear Side
Boot Kit
Wheel Side
Boot Kit
CV Joint
7.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAUTION
7.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Special Tools
SPX Corporation - 1-800-328-6657 or http://
polaris.spx.com
TOOL
PART NUMBER
DESCRIPTION
2871695 (Part of 2871702 Kit) Backlash Setting Tool
Rear Output Seal
2871698 (Part of 2871702 Kit)
Driver
Rear Driveshaft Seal
2871699 (Part of 2871702 Kit)
Guide
Bearing Seal Driver
2871282
(50 mm)
Lubrication
Refer to Chapter 2 for transmission lubricant type and
capacity.
8.2 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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B
A
A
=T
A = Frame Long Bolts = 37 ft. lbs / 50Nm
B = Side Fasteners = 37 ft. lbs / 50Nm
A
UPPER MOUNT BRACKET
=T
A = Upper Bracket-to-Frame Fasteners =
20ft. lbs / 27Nm
B = Bracket-to-Transmission Bolt = 37 ft. lbs / 50Nm
8.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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C
A
REAR STABILIZER
C
B
=T
A = Stabilizer-to-Frame Fasteners = 20ft. lbs / 27Nm
B = Stabilizer-to-Transmission Bolt = 37 ft. lbs / 50Nm
C = Stabilizer-to-Transmission Fasteners =
37 ft. lbs / 50Nm
8.6 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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• Seat
• Side Panels
Mount
from each side. 8
14. Remove the upper transmission support bracket
completely from the ATV.
Screw 15. With the help of an assistant, lift and remove
Shift transmission out of rear of frame while pulling the
Handle output shaft from the propshaft yoke.
• Seat
• Side Panels
8.8 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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8
23-27 ft. lbs.
(31-37 Nm)
8-12 ft. lbs.
(11-16 Nm)
242 ® 8-12 ft. lbs.
(11-16 Nm) 242 ®
FOR REASSEMBLY
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
10-14 ft. lbs.
(14-19 Nm)
Apply Loctite® to
12-18 ft. lbs. 8-12 ft. lbs. the bolt threads.
(16-24 Nm) (11-16 Nm)
8.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Transmission Disassembly
NOTE: Refer to the exploded view at the end of this
chapter as a reference.
10. Remove the shift shaft (J), detent pawl (K) and the
shift gears (L and M).
N O
P Q Q
R
S
8.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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T
U
16. Using a T27 Torx driver, remove the screws that 19. Place the gear cluster assembly on a clean surface for
secure the output gear (U). inspection.
25. Remove the rest of the ball bearings from each shaft.
Figure 8-1
8.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAUTION PA-50231
33. Remove the snap ring and shim from the snorkel
shaft.
Snap Ring 8
Locking Screw
Shim
31. Remove the seal from the snorkel shaft to access the
snorkel tube for removal.
Seal Removed
Snap Ring
Grease Threads
38. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.
8.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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PA-50231
=T
4. Inspect the output gear assembly and replace
bearings if needed. Inspect each gear for damage,
Output Gear Retaining Screws:
chips or abnormal worn teeth.
8-12 ft. lbs. (11-16 Nm)
=T
Snorkel Locking Screw:
10. Check the output shaft gear backlash again by feel. If 8-12 ft. lbs. (11-16 Nm)
the output shaft lash appears to be too tight, rotate the
13. With the snorkel shaft assembly properly installed,
snorkel shaft counterclockwise to the next notch.
remove the (4) Torx screws and remove the output
11. Once the backlash is set, apply Loctite 242® to the shaft assembly.
threads and install the locking screw to secure the
snorkel tube.
8.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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= In. / mm.
4. The shift drum, reverse shaft, input shaft, shift fork rail
and output gear assembly must be installed at the
same time to properly align all components.
Reverse Shaft
Tie Strap
=T
Oil Deflector Retaining Screws:
20-30 in. lbs. (2.3-3.4 Nm)
8.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Top View
Tensioner Cam
• Place the spring over the front pin and hook the
spring leg under the cam.
View From Left Side of Transmission
Forward
9. Tensioner Installation:
=T
Gearcase Cover Bolts:
25-30 ft. lbs. (34-41 Nm)
11. Install all new seals into the gearcases. Use the Rear
Output Seal Driver (PN 2871698) and Rear Driveshaft
Seal Guide (PN 2871699) to install the seals into the
gearcase halves (refer to the following illustration to
identify the seals needing replacement).
13. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
2871698 into the bushing pocket on the left side. Align the
timing marks on the gears as shown.
2871699
Timing Marks
14. Install the lockout disc onto the shift drum shaft. Be
sure to install the lockout disc with the raised edge
facing outward.
Lockout Disc
8.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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=T
Sector Cover Bolts:
8-12 ft. lbs. (11-16 Nm)
19. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the
nut and torque to specification.
Detent Star
=T
Bellcrank Nut:
16. Install the detent pawl onto the shift shaft and carefully
12-18 ft. lbs. (16-24 Nm)
install the compression spring.
20. Install the shift shaft onto the bellcrank end (if
removed) and secure with the snap bushing.
Spring
Snap Bushing
Clip
Detent Pawl
O-Rings
NOTES
8.24
NOTE: Refer to tightening procedures in this chapter. Some special procedures are used when torquing
certain bolts and fasteners.
9.2 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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The Polaris disc brake system consists of the following This system also incorporates a diaphragm (E) as part of
components or assemblies: brake lever; master cylinder; the cover gasket; and a vent port (F) located between the
hydraulic hose; brake calipers (slave cylinder); brake gasket and the cover. The combination diaphragm and
pads; and brake discs, which are secured to the drive line. vent allow for the air above the fluid to equalize pressure
as the fluid expands or contracts. Make sure the vent is
9
open and allowed to function. If the reservoir is over filled
or the diaphragm vent is plugged the expanding fluid may
build pressure in the brake system leading to brake fail
9.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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=T
Bleeder Screw Torque:
25-30 in.lbs. (2.80-3.40 Nm)
Torque Inner
Bolt First
Diaphragm
9.6 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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2
1
3
4
2
6
3
9
3
2
9.8 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
B 3
E
G
H
C
D
3 F
9.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
30-35 ft.lbs. 3G B
(41-48 Nm) H 25-30 in lbs.
(2.80-3.40 Nm)
I
A. Anvil Bolts
K F B. Bleed Screws
3 C. Washers
D. O-rings
E. Rear Housing
F. Seals
G. Piston
M J H. Slide Pins
I. Bushings
J. Seal
K. Bracket
L. Pad
M.Front Housing
N. Retaining Clips
N L
B 3
E
C
G
H
9
A. Socket Set Screw
B. Bleeder Screw D
C. Caliper Asm.
D. Boot F
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake PAds
CAUTION
9.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAUTION
Measure Pad
= In. / mm.
WARNING
9.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
= In. / mm.
= In. / mm.
= In. / mm.
=T
Brake Disc Bolt Torque:
Front - 18 ft.lbs. (24 Nm)
Rear - 27 ft.lbs. (37 Nm)
CAUTION
9.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAUTION
Clean Components
Front Caliper Piston Bore I.D.: 3. Lubricate the mounting bracket pins with disc brake
Service Limit: 1.193” (30.30 mm) caliper lube, and install the rubber dust seal boots.
9.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Installation
5. Install caliper on hub strut, and torque mounting bolts
to specification.
15 ft.lbs. (21 Nm)
8. Perform brake bleeding procedure as outlined earlier
in this chapter.
18 ft.lbs.
(24 Nm)
=T 9
Brake Caliper Mounting Bolt Torque:
18 ft.lbs. (24 Nm)
9.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Measure
Thickness
= In. / mm.
=T
Rear Brake Pad Thickness
Service Limit: .180” (4.6 mm) Caliper Mount Bolt Torque:
18 ft.lbs. (24 Nm)
Touring Pad Installation 4. Slowly pump the brake lever until pressure has been
built up. Maintain at least 1/2, (12.7 mm) of brake fluid
1. Lubricate mounting bracket pins with a light film of
in the reservoir to prevent air from entering the brake
disc brake caliper lube, and install rubber dust boots.
system.
9
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other.
Measure
Thickness
4. Remove caliper mounting bolts and lift caliper off of
disc.
= In. / mm.
9.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Install Pads
30-35 ft.lbs.
(41-48 Nm)
WARNING =T
If the brake pads are contaminated with grease, Caliper Slide Bolt Torque:
oil, or liquid soaked do not use the pads, 30-35 ft.lbs. (41-48Nm)
use only new clean pads.
5. Slowly pump the brake lever until pressure has been
2. Install and tighten the slide pin with a hex wrench. built up. Maintain at least 1/2, (12.7 mm) of brake fluid
3. Install caliper and torque the mounting bolts to in the reservoir to prevent air from entering the master
specification. cylinder.
6. It is recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
=T
Caliper Mount Bolt Torque:
18 ft.lbs. (24 Nm)
Removal
CAUTION
Clean Components
9.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Rear Caliper Piston Bore I.D. 3. Lubricate the mounting bracket pins with disc brake
Service Limit: 1.193” (30.30 mm) caliper lube, and install the rubber dust seal boots.
B
A
Seal
Pistons & O-ring
Anvil Bolts
9.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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O-ring
Inspect
Bushing
Seals
= In. / mm.
18 ft.lbs.
(24 Nm)
=T
=T
Caliper Mounting Bolt Torque:
16-18 ft.lbs. (22-24 Nm)
Caliper Anvil Bolt Torque:
16-18 ft.lbs. (22-24 Nm) 5. Install brake line and tighten securely with a line
wrench. Torque the brake lines to the proper torque
3. Install brake pads in caliper body with friction material
specification.
facing each other. Install the slide pins and the slide
pin retaining rings. Torque the slide pins to 6. Follow bleeding procedure outlined in the
specification. “BLEEDING PROCEDURE” in this chapter.
NOTE: The slide pins should be torqued when 7. Field test unit for proper braking action before putting
installed on caliper mount. into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when lever is
released. If the brake drags, re-check assembly and
installation.
=T
Slide Pin Torque:
30-35 ft.lbs. (41-48 Nm)
9.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Inspection
= In. / mm.
1. Visually inspect disc for scoring, scratches, or
gouges. Replace the disc if any deep scratches are
evident. Brake Disc Runout
Service Limit: .010” / .254 mm
2. Use a micrometer and measure disc thickness at 8
different points around perimeter of disc. Replace
disc if worn beyond service limit.
Disc Thickness
= In. / mm.
J I
A
H
F E
9.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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CAP
CAP
REAR RESERVOIR
FOOT PEDAL
Overview • Test for brake drag after any brake system service
and investigate cause if brake drag is evident.
Polaris disc brake systems are light weight, low
maintenance and perform well in the conditions ATV’s • Make sure caliper moves freely on guide pins
routinely encounter. However, there are a few things to (where applicable).
remember when replacing disc brake pads or performing
brake system service to ensure proper system function • Inspect caliper piston seals for foreign material
and maximum pad service life. that could prevent caliper pistons from returning
freely.
• Perform a brake burnishing procedure after
installing new pads to maximize service life.
CAUTION
• Optional pads are available to suit conditions in
your area. Select a pad to fit riding style and Use only DOT-approved brake fluid as an assembly 9
environment. aid for all procedures described in this chapter to
prevent brake system contamination.
• Do not over-fill the master cylinder fluid reservoir. DO NOT USE LUBRICANTS OF ANY KIND FOR
• Make sure the brake lever and pedal returns freely ASSEMBLY, AS THEIR USE CAN CAUSE
and completely. RUBBER COMPONENTS TO SWELL.
=T
Banjo Bolt Torque:
15 ft.lbs. (21 Nm)
Frame
Rear Brake MC
Brake Mount
Spring
Brake Lever
=T
Master Cylinder to Frame Bolt Torque:
8 ft.lbs. (11 Nm)
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=T
Master Cylinder to Frame Bolt Torque:
8 ft.lbs. (11 Nm)
A SPORTSMAN
B
J
C
15 ft.lbs.
(21 Nm)
A. Brake Reservoir
B. Rear Foot Brake Line
C. Rear Master Cylinder
D D. Master Cylinder Bolts
E. Bushing
K F. Washer
G. Cotter Pin
I H. Foot Pedal
I. Mount Plate Bolts
9
J. Mount Plate
F K. Spring
G E H
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
Brakes Lock
• Alignment of caliper to disc
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10
• Become familiar with the operation of your meter. • ETC switch mis-adjusted or faulty
Be sure leads are in the proper jack for the test
being performed (i.e. 10Ajack for current • Wire harness or connections wet, corroded or
readings). Refer to the Owner’s manual included broken
with your meter for more information.
• Poor ignition coil ground
• Voltage, amperage, and resistance values
• Incorrect wiring after repair (inspect color coding in
included in this manual are obtained with a FlukeÔ
connectors, etc.)
77 Digital Multimeter (PV-43568). This meter is
used for when diagnosing electrical problems. • Faulty ignition coil windings (measure resistance
Readings obtained with other meters may differ. of primary and secondary)
• Pay attention to the prefix on the multimeter • Sheared flywheel key
reading (K, M, etc.) and the position of the decimal
point. • Flywheel Loose or damaged
• For resistance readings, isolate the component to • Excessive crankshaft runout - should not exceed
be tested. Disconnect it from the wiring harness or .0024”
power supply.
• Faulty ECU
• Faulty CPS
• Low Battery
10.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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(A) Needle (also flashes during warning condition) The Polaris ATV Instrument Cluster is powered by battery
(B) Speedometer voltage (12 VDC) and requires inputs from the engine
in MPH/KPH RPM, transmission gear, and transmission speed sensor
for proper operation. Two harnesses plug into the cluster
head; one from the transmission speed sensor, and one
from the vehicle main harness. A non-serviceable internal
memory battery maintains odometer and hour meter data
when the machine is not running. The illumination lamp
inside the gauge is non-serviceable and is designed to last
for the life of the unit. (A) The speedometer needle
indicates speed from an electronic wheel speed sensor
located on the transmission and the needle also flashes
International Speedometer during a warning condition. The speedometer needle
indicates speed in MPH and KPH. NOTE: A flashing
needle could indicate a hot engine, low battery
warning, or the No. 10 Pin could be grounded. (B) The
speedometer features numbers in Mile Per Hour (MPH)
and Kilometers Per Hour (KPH). (C) The Rider
ILL. 1
(C) Rider Information Center Information Center performs a number of functions (See
Illustration 2):
(B) Speedometer
(A) Needle in MPH/KPH 1. Odometer / Tachometer / Trip meter / Hour Meter /
Clock
7 9 8 ILL. 2
• Service Interval - The purpose of the • The segments of the fuel gauge indicate the level
programmable service interval is to provide the of fuel in the fuel tank. When the last segment
consumer and the dealer with a convenient way to clears, a low fuel warning is activated. All related
schedule routine maintenance. When the ATV icons will flash, “FUEL” will display in the LCD, and
leaves the factory, this feature is set at “50 hours". the speedometer needle will blink. If riding, be
When the first 50 hours of engine operation are sure to refuel immediately.
finished the wrench icon will flash for 10 seconds
each time the ATV is started as a reminder that
ATV maintenance is due. NOTE: To reset the
Service Interval, follow the directions for
“SETTING NEW SERVICE INTERVAL” later in this
chapter.
6. AWD Indicator
7. Gear Indicator
8. Mode Indicator
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AWD On
Ill. 2 10
23 Ohms in Park
Once the service interval mode is set with the hours when
service is due, the hours of actual engine operation are
subtracted from the set hours until 0 is reached. When the
counter reaches 0, the wrench icon will flash quickly for 10
seconds each time the vehicle is started as a reminder that
the periodic maintenance is due.
75 Ohms in Reverse
10.8 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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1. While in the service interval mode, press and hold the The display in the trip meter and odometer can be
mode/override button until the wrench icon flashes. changed to display either kilometers or miles. The current
When it begins to flash, release the button. display mode will be shown as “KM” or “MP”. To change,
2. The setting will increase by one hour each time the hold in the mode button until the letters flash, then press
button is pressed. Pressing and holding the button will and release the button once. When the display stops
allow the numbers to escalate much faster. flashing, the mode has been set.
3. When the desired time increment is displayed,
release the button and wait for the wrench to stop
flashing. When the wrench stops blinking, your
service hours are set.
NOTE: If you scroll past the intended number, hold
the button down until the count turns over to 0. You
can then reset the number.
10
ON
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Align
Pod
10
Push Instrument
Cluster Outward
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10.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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TEST 6 - Vehicle Speed Sensor 2. Connect the wires from the Static Timing Light
Harness to the sensor 3 pin connector using the Hall
Speed Sensor Location Sensor Probe Harness (PN 2460761).
The speed sensor is located on the RH transmission case 3. Pass a screwdriver back and forth in front of the
and can be accessed through the rear RH wheel well area. sensor tip.
4. Be sure connections are good and 9V battery is in
good condition. If the light flashes, the sensor is good.
10
Speed Sensor
10.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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• Verify the AWD switch is functional. NOTE: The fan may not function or operation may
• Verify the AWD hub coil is functional. Test the be delayed if coolant level is low or if air is trapped in
AWD hub coil using an ohm meter. the cooling system. Be sure cooling system is full
and purged of air. Refer to Maintenance Chapter 2
for cooling system information.
EFI Shown
Fan Control Bypass Test - EFI
1. Disconnect harness from coolant temperature sensor
on engine.
2. With the ATV in “Park” and with the parking brake on,
turn the ignition key and engine stop switch “ON”.
Start the engine. The fan should start running.
3. If the fan does not run or runs slowly, check the fan
motor wiring, ground, motor condition for proper
operation (refer to “FAN MOTOR CURRENT DRAW”
in this section). Repair or replace as necessary. If the
AWD Hub Coil Resistance: fan runs with the sensor harness disconnected, but
24 ± 5% will not turn on when the engine is hot, check the
coolant temperature sensor, wires, grounds,
connector terminals.
• Verify the wiring harness, wiring, connectors,
connector pins and grounds are undamaged, Fan Control Bypass Test - H.O.
clean and connect properly.
1. Disconnect harness from the fan switch on engine.
• Verify continuity of wire connections with a known 2. Apply 12 Vdc current and ground directly to the fan
good volt/ohm meter. harness terminals. Refer to the wire schematic.
IMPORTANT: Verify all wires and wiring connections 3. If the fan does not run or runs slowly, check the fan
have been tested properly with a known good volt/ motor wiring, ground, motor condition for proper
ohm meter before suspecting a component failure. operation (refer to “FAN MOTOR CURRENT DRAW” 10
80% of all electrical issues are caused by bad/failed in this section). Repair or replace as necessary. If the
connections and grounds. fan runs with direct 12Vdc applied (harness
disconnected), but will not turn on when the engine is
hot, check the fan switch, fan relay, wires, grounds
and connector terminals.
H.O.
1. Disconnect the harness from the coolant sensor
(EFI).
2. Connect a DC ammeter in-line on the fan switch
harness wires. See illustration.
(H.O. Models - An inductive ammeter is required)
3. Be sure fan blade is free to rotate.
4. Turn ignition key and engine stop switch to “ON” E.F.I.
position. Read the current draw on ammeter with fan
running.
(H.O. Models - Direct 12 Vdc to fan required)
5. If the fan motor draws more than 10 Amps, replace the
motor.
Table 10-1: EFI Sensor
Fan Motor Current Draw:
Should Be Less Than 10 Amps TEMPERATURE F (C) RESISTANCE
NOTE: Fan motor current draw specification may 68F (20 C) 37.3 k
vary on Sportsman H.O. and EFI models. 212F (100 C) 2.1 k
10.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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10
ETC Test
1. Remove throttle block cover by carefully releasing all
tabs around edge of cover.
2. Place transmission in neutral and apply parking
brake.
3. Start engine and open throttle lever slightly until
engine RPM is just above idle speed.
4. Hold throttle cable with fingers at point “A” as shown
below and release throttle lever. If the ETC system is
functioning properly, the engine will lose spark and
stop.
10.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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EFI - Instead of generating DC voltage via flywheel magnetic induction, a 12 Vdc current is supplied from the Ignition/Fuel Pump Relay to the Ignition
coil. At the ECU, a small A/C signal from the CPS helps the ECU pre-determine Top Dead Center (TDC), which in turn signals the ECU to release
the electrical charge collapsing the coil field for ignition (based on the ECU timing map).
CDI- A 12 volt DC current is supplied directly from the battery to the CDI. At the CDI, a DC current is supplied to the coil for the initial ignition charge.
A small A/C signal from the stator pulse coil triggers the CDI to fire the coil.
DC/ignition systems have the ability to ignite with as little as 6 volts of power.
SPORTSMAN
Carbureted
10
10.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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10
CONNECT GAP
TEST READING
TESTER TO:
White/Blue spark
Spark Gap Spark plug lead and
jumps 1/4" (6mm)
Output Test ground
gap
CHARGING SYSTEM
Crankshaft Position Sensor Gap:
0.4 - 1.2 mm (0.015 - .047 in.) Current Draw - Key Off
No Spark, Weak, or Intermittent Spark Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will
• Spark plug gap incorrect occur to electrical components.
• Fouled spark plug
Connect an ammeter in series with the negative battery
• Faulty spark plug cap or poor connection to high cable. Check for current draw with the key off. If the draw
tension lead is excessive, loads should be disconnected from the
system one by one until the draw is eliminated. Check
• Related wiring loose, disconnected, shorted, or component wiring as well as the component for partial
corroded shorts to ground to eliminate the draw.
• Engine Stop switch or ignition switch faulty Current Draw Inspection (key off)
• ETC switch mis-adjusted or faulty
• Faulty ECU
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WARNING
10.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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10.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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The relays, located under the front storage box, assist with KEY-ON Battery power supply,
component operation such as the fan, fuel pump, etc. Red/White switched on by the key and LH control
switches, enables power to relay.
The fan relay, controlled by the ECU, operates the fan.
Relay “ON” command. The ECU
(Carbureted model also utilizes a fan relay)
supplies a ground which closes the
Gray/Black
The ECU relay, controlled by the key switch, operates the relay, supplying power to run the fuel
ECU pump, injectors, etc.
Fused 15-amp, unswitched battery
The Ignition Coil and Fuel Pump relay, controlled by the Red power IN supply for EFI component
ECU, turns on power for components such as the fuel
operation.
pump, injectors, etc.
EFI power output. 'ON' when ECU
sends a signal on the GRY/W wire,
Red/Black closing the relay. Supplies 15-amp
power for ECU-operation of EFI
components.
EFI
CAUTION
Loosen Tighten
10.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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A
Pull Upward
C
10
25’ (7.6 m)
Lamp Center Height
2” (5.1 cm)
LOW
Remove Install
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Loosen Screw
4. Install the harness assembly into the headlight
assembly. Turn the headlight harness clockwise to
secure the headlamp into place.
A Yellow
Brown
A
Green
10.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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ECU
Remove
Brake Switch
Location
Fuel Sender
Empty: 6
Half
Full
=T
Speed Sensor Bolt Torque
8-12 ft. lbs. (11-17 Nm)
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10
Internal
Harness
Non
Serviceable
Shims
CAUTION
NOTE: Note the alignment marks on both ends of
the starter motor casing. These marks must align
during reassembly. Some cleaning solvents may damage the insulation
in the starter. Care should be exercised when
3. Remove the rear brush housing assembly, holding the selecting an appropriate solvent. If the commutator
front housing and armature assembly together. needs cleaning use only electrical contact cleaner.
10.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Brush Length
Brush Replacement
1. Install a new carbon brush assembly in the brush 4. Measure the resistance between each commutator
housing. NOTE: Be sure that the terminal bolt segment and the armature shaft. The reading should
insulating washer is properly seated in the housing, be infinite (no continuity).
and the tab on the brush plate engages the notch in
the brush plate housing.
CAUTION
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H
G
A F
D
A. Gear Assembly E
B. Thrust Washer C
C. Bushing
D. Retaining Ring
E. Thrust Washer F.
Stopper
G. Cover
H. Spring
Yes
Disconnect coil engagement wire from the starter Check voltage on both sides of circuit
solenoid. Connect tester black wire to battery breaker, ignition switch/engine stop switch.
ground. Connect red tester lead to harness wire at The voltage on both sides should be the same.
No NOTE: The ignition switch and engine stop
solenoid. Turn on ignition switch. Tester should
read battery voltage. switch must be ‘on’. Replace component if
failed .
Reconnect the solenoid. Connect the tester black No Clean the battery-to-solenoid cable ends
lead to the battery positive and the red lead to the or replace the cable.
solenoid end of the battery-to-solenoid wire.
Depress starter button. Reading should be less than
.1 Vdc
Yes
Yes
Yes
If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.
10.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Your ATV may have a Conventional Battery or a Sealed Authorized Polaris dealers/distributors are required to use
Low Maintenance Battery. To identify which type of battery the conductance analyzer when testing 12V Polaris
your ATV has, refer to the illustration below and follow the batteries.
correct service and charging procedures that follow in the
manual.
Conventional Battery
Removable
Caps
Top View
Electrolyte Level
Indicator
Polaris MDX-610P
SPX PN: PU-50296
Sealed Low
Maintenance Battery
No Caps (Non-
Removable)
Top View
10
No Electrolyte
Level Indicator
WARNING
10.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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Inspect the battery fluid level. When the battery fluid nears
WARNING
the lower level, remove the battery and fill with distilled
water only to the upper level line. To remove the battery:
Vent tube must be free from obstructions and kinks and
securely installed. If not, battery gases could accumulate
and cause an explosion. The vent tube should be routed
away from frame and body to prevent contact with Route
Maintain the cables correctly.
between
upper and 5. Reinstall the holder strap.
lower level
marks
Conventional Battery Testing
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
CAUTION
10
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last!
Battery Hydrometer (PN 2870836) NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
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10.52 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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1.265 -75° F
1.225 -35° F
1.200 -17° F
1.150 +5° F
1.100 +18° F
10
1.050 +27° F
10.54 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
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10
1 4
6 2
5
8
7
5 3
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To Install
A B
To Remove
10
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10
NOTES
10.60