Find great deals on eBay for Polaris Sportsman Manual in Other Makes. Shop with Polaris Sportsman / Service Repair Manual. $ View and Download Polaris Sportsman EFI owner’s manual online. Polaris ATV Owner’s Manual. Sportsman EFI Offroad Vehicle pdf manual. Sportsman / EFI ATV Service Manual (PN ) ECopyright Polaris Sales Inc. All information contained within this publication is based .

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Remove fill plug C. The ring may lose sealing surfaces. Service Manual CD Rom. Install the head gasket A on the cylinder B. See page for the part numbers of Polaris products. PVT seals should be inspected for damage if repeated leaking occurs.

Make sure caliper moves freely on Polaris disc brake systems are light weight, low guide sporrtsman where applicable.

Owner’s Manuals

Support bottom of bearing carrier housing. See notes secure handlebars in this position. Be sure breather line is routed properly and secured in place.

Refer to Maintenance Chapter 2 for more information. Torque thermostat housing 8.

Page 32 Never modify the ATV through improper installation or use of accessories. Check for movement of the shaft in the stationary 9. Note the positions of the gears in the photo. Top End Apply 0W to lifters. Helmet Your helmet is the most important piece of protective gear for safe riding.



Rear Gearcase Installation 2. Change oil immediately and monitor level. Install new seals into the gearcase housing and gearcase housing cover. Side panel removal is quick and easy, use the NOTE: Remove primer plug from the engine. Install the small clamp on the boot.

To remove the water pump seal, the Slide positive brush springs to the side, pull reassembly. Remove wheel, brake caliper and wheel hub. Everything as listed p m Spark plug condition is indicative of engine operation. Start bearing in housing. Compress spring using strut spring compressor tools. Torque to the starter drive. Place armature in a growler. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.

Inspect O-ring and replace if damaged.

Spin the bearing to check the ball bearings for smoothness. Do not service while headlight is hot. Install piston D with a twisting motion while pushing inward. Page 67 Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust.



Repeat procedure Steps for the remaining caliper s. Be sure the storage area is well ventilated, and cover the machine with 2004 genuine Polaris ATV cover. Polaris recommends the use of Polaris special tools when servicing any Polaris product.

Shift Linkage Rod 4.

Use of lubricants oil, soapy water, etc. Insert bearing carrier on drive shaft.

Separate the crankcase halves If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Page All operating and control functions within the ECU are pre–set.