Polaris Sportsman 400 User manual

CHAPTER INDEX
CHAPTER 1 GENERAL
CHAPTER 2 MAINTENANCE
CHAPTER 3 ENGINE
CHAPTER 4 FUEL SYSTEM/CARBURETION
CHAPTER 5 BODY / SUSPENSION
CHAPTER 6 PVT SYSTEM
CHAPTER 7 FINAL DRIVE
CHAPTER 8 TRANSMISSION
CHAPTER 9 BRAKES
CHAPTER 10 ELECTRICAL

1
CHAPTER 1
GENERAL INFORMATION
Model Identification 1.1...........................
Serial Number Location 1.1.......................
Replacement Keys 1.2............................
Model Color Identification 1.3-1.7......................
Machine Dimensions 1.8-1.10..........................
Specifications - Sportsman 400 1.11-1.12.................
Specifications - Sportsman 500 DUSE 1.13-1.14..........
Specifications - Sportsman 500 H.O. 1.15-1.16............
Publication Numbers 1.17..........................
Paint Codes 1.17.................................
Standard Torque Specifications 1.18................
Torque Conversion Table 1.19-1.20......................
Decimal Equivalent Chart 1.21......................
Conversion Table 1.22.............................
Tap Drill Charts 1.23...............................
Glossary of Terms 1.24-1.25............................

GENERAL INFORMATION
1.1
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
Year Designation Basic Chassis
Designation Engine Designation
A01CH50AA Emissions &
Model Option
ENGINE DESIGNATION NUMBERS
42 EH42PLE05 Single, L/C, SOHC 4 Stroke, Electric Start............
50 EH50PLE09/13 Single, L/C, SOHC 4 Stroke, Electric Start..........
VIN IDENTIFICATION
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17
4XACH 50A*1P000000
Vehicle Descriptor Vehicle Identifier
PowertrainEngine
Emissions Model
YearPlant No. Individual Serial No.
Body Style
Check Digit
World Mfg. ID
* This could be either
a number or a letter
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION
Themachinemodelnumberandserialnumberare
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)
TRANSMISSION I.D. NUMBER
LOCATION
The transmission I.D. number is located
on top of the transmission snorkel, right
side of machine.
A
B
Front

GENERAL INFORMATION
1.2
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.
Series # Part Number
31 4110141
32 4110148
67 4010278
68 4010278
27 4010321
28 4010321
31XX
Key Series
Number

SPORTSMAN 400 - A01CH42AB
SPORTSMAN 400 - A01CH42AA
GENERAL INFORMATION
1.3
MODEL COLOR IDENTIFICATION

SPORTSMAN 400 - A01CH42AC
GENERAL INFORMATION
1.4
MODEL COLOR IDENTIFICATION

SPORTSMAN 500 H.O. - A01CH50AB
SPORTSMAN 500 H.O. - A01CH50AA
GENERAL INFORMATION
1.5
MODEL COLOR IDENTIFICATION

SPORTSMAN 500 DUSE - A01CH50AD
SPORTSMAN 500 H.O. - A01CH50AE
GENERAL INFORMATION
1.6
MODEL COLOR IDENTIFICATION

SPORTSMAN 500 H.O. DUSE - A01CH50AF
SPORTSMAN 500 H.O. RSE - A01CH50AJ
GENERAL INFORMATION
1.7
MODEL COLOR IDENTIFICATION

SPORTSMAN 500
SPORTSMAN 400
30 in
76.2 cm
45 in
114.3 cm
41 in
104.1 cm
22 in
55.8 cm
22 in
55.8 cm
42 in
106.6 cm
46 in
116.8 cm
32 in
81.2 cm
GENERAL INFORMATION
1.8
MACHINE DIMENSIONS