Polaris Sportsman 300-400 (2009)
POLARIS SPORTSMAN 300-400 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
POLARIS SPORTSMAN 300-400 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to ATV Polaris Sportsman 300-400 (2009). CONTENTS: VEHICLE IDENTIFICATION - Model Identification - Engine Designation Number - Vehicle Identification Number (VIN) - Vehicle and Engine Serial Number Locations SPECIFICATIONS - MODEL: 2009 SPORTSMAN 300 - MODEL: 2009 SPORTSMAN 400 H.O. - MODEL: 2009 SPORTSMAN 300 - MODEL: 2009 SPORTSMAN 400 H.O. VEHICLE INFORMATION - Publication Numbers - Replacement Keys - Special Tools MISC. SPECIFICATIONS AND CHARTS - Standard Torque Specifications - SAE Tap Drill Sizes - Metric Tap Drill Sizes - Decimal Equivalents - Conversion Table - Glossary Of Terms PERIODIC MAINTENANCE CHART - Periodic Maintenance Overview - Break-In Period - Maintenance Chart Key - Maintenance Intervals - Grease Lubrication Points - Maintenance quick reference LUBRICANTS / SERVICE PRODUCTS - Polaris Lubricants,Maintenance and Service Products GENERAL VEHICLE INSPECTION AND MAINTENANCE - Pre-ride / Daily Inspection - Frame, Nuts, Bolts, Fasteners - Controls - Handlebar Component Locations FUEL SYSTEM AND AIR INTAKE - Fuel System - Fuel Lines - Fuel Filter - Vent Lines - Throttle Operation - Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment - Choke (Enricher) Adjustment - Fuel Valve - Carburetor Draining - Pilot Screw Location - Pilot Screw and Idle Speed Adjustment - Main Air Filter Cleaning - Air Filter / Pre-Filter Service (300) - Air Filter / Pre-Filter Service (400 H.O.) - Air Box Sediment Tube ENGINE - Engine Oil Level (Sportsman 300) - Engine Oil and Filter Change (Sportsman 300) - Engine Oil Level (Sportsman 400 H.O.) - Engine Oil and Filter Change (Sportsman 400 H.O.) - Oil Pump Priming Procedure (Sportsman 400 H.O.) - Engine Breather Hose - Engine Breather Filter (Sportsman 300) - Engine Breather Filter (Sportsman 400 H.O.) - Valve Clearance (Sportsman 300) - Valve Clearance (Sportsman 400 H.O.) - Recoil Housing - Compression and Leakdown Tests - Exhaust Silencer Cleaning - Engine Mount Fastener Torque TRANSMISSION / FRONT GEARCASE - Transmission Lubrication - Front Gearcase Lubrication COOLING SYSTEM (400 H.O.) - Cooling System Overview - Coolant Level Inspection - Coolant Strength / Type - Cooling System Pressure Test - Cooling System Hoses - Radiator - Coolant Drain / Radiator Removal CVT / FINAL DRIVE / WHEEL AND TIRE - CVT Drying - Drive Shaft Boot Inspection - Wheel and Hub Torque Table - Wheel Removal - Wheel Installation - Tire Pressure - Tire Inspection ELECTRICAL AND IGNITION SYSTEM - Battery Maintenance - Battery Removal (Sportsman 300) - Battery Installation (Sportsman 300) - Battery Removal (Sportsman 400 H.O.) - Battery Installation (Sportsman 400 H.O.) - Spark Plug Service STEERING AND SUSPENSION - Steering Inspection - Tie Rod End / Steering Inspection - Camber and Caster - Toe Alignment - Toe Alignment Adjustment - Suspension Inspection - Suspension Spring Preload Adjustment BRAKE SYSTEM - Brake Fluid Inspection - Brake Pad Inspection - Hose / Fitting Inspection - Brake Pedal Freeplay TOOLS - Special Tools TORQUE SPECIFICATIONS - Engine Torque Specifications - Torque Pattern (Cylinder Head) GENERAL ENGINE SERVICE - Engine Exploded View - Engine Service Data - Engine Service Data - Oil Flow Diagram - Piston Identification - Piston Ring Identification - Accessible Components ENGINE SERVICE - Engine Removal - Engine Lubrication - Oil Flow / Pressure Test - Engine Breather / Oil separator - Cam Chain Tensioner Removal - Cam Chain Tensioner Inspection - Rocker Arm / Rocker Arm Shaft Disassembly and Inspection - Camshaft Removal - Camshaft Inspection - Cylinder Head Removal - Cylinder Head Inspection - Cylinder Head Warp Inspection - Combustion Chamber Inspection - Cylinder Head Disassembly - Valve Inspection - Valve Seat Reconditioning - Cylinder Head Assembly - Valve Sealing Test - Engine Bottom End Disassembly - Cam Chain Guide And Tensioner Blade - Piston Removal - Cylinder Inspection - Cylinder Hone Selection / Honing Procedure - Honing To Deglaze - Piston Inspection - Piston Ring Installed Gap - Flywheel Removal / Inspection - Starter Drive Removal / Inspection - Cam Chain Drive Sprocket Removal / Inspection - Oil Pump Inspection / Removal - Starting Clutch and Engine Braking Clutch Removal / Inspection - Starting Clutch Assembly - Starting Clutch Exploded View - Crankcase Disassembly - Crankcase Separation - Crankshaft Removal - Crankshaft / Cam Chain / Sprocket Inspection - Crankcase Oil Passages & Pressure Relief Valve - Camshaft Chain - Balance Shaft Bearing Inspection - Crankcase Oil Pickup Strainer Inspection - Bearing / Seal Installation - End Play Inspection / Adjustment - Crankshaft End Play Adjustment - Balancer Shaft End Play Adjustment - Crankcase Reassembly - Cam Chain, Oil Pump, & Tensioner Blade Installation - Piston Ring Installation - Piston Installation - Cylinder Installation - Cylinder Head and Camshaft Installation - Camshaft Installation & Timing - Cam Chain Tensioner Installation - Rocker Arm Installation - Starter Drive Assembly - Engine Installation Notes TROUBLESHOOTING - Spark Plug Fouling troubleshooting - Engine Troubleshooting SPECIAL TOOLS SPECIFICATIONS - Torque Specifications - Engine Service Data - Engine Service Data - Engine Fastener Torque Patterns GENERAL ENGINE SERVICE - Accessible Components - Engine Removal - Crankshaft Straightening - Engine Lubrication - EH460PLE020 - Oil Pressure Test - EH460PLE020 - Oil Flow - EH460PLE020 - EH460PLE020 Oil Flow Diagram - EH460PLE020 Engine Exploded View COOLING SYSTEM - Cooling System Specifications - Cooling System Layout and Testing ENGINE DISASSEMBLY - Cam Chain Tensioner / Rocker Arm / Camshaft Removal - Cam Chain Tensioner Inspection - Rocker Arm / Shaft Inspection - Camshaft Removal - Automatic Compression Release Removal / Inspection - Automatic Compression Release Installation - Camshaft Inspection - Cylinder Head Removal - Cylinder Head Exploded View, EH460PLE020 - Cylinder Head Inspection - Cylinder Head Warpage - Cylinder Head Disassembly - Valve Inspection - Combustion Chamber - Valve Seat Reconditioning - Cylinder Head Assembly - Valve Sealing Test - Valve Clearance Adjustment - Cylinder / Piston Removal and Inspection - Piston Removal - Cylinder Inspection - Cylinder Hone Selection / Honing Procedure - Honing to Oversize - Cleaning the Cylinder After Honing - Piston-to-Cylinder Clearance - Piston / Rod Inspection - Piston Ring Installed Gap - Starting Clutch Removal / Inspection - Starting Clutch Assembly - Starting Clutch Exploded View - Crankcase Disassembly - Starter Drive Removal / Inspection - Flywheel and Stator Removal / Inspection - Cam Chain / Tensioner Blade - One Way Valve - Crankcase Separation - Oil Pump Removal / Inspection - Oil Pump Assembly - Counter Balancer Shaft Removal / Inspection - Crankshaft Removal / Inspection - Crankcase Bearing Inspection - Oil Seal / Mechanical Seal Removal (Engine Disassembled) - Crankcase Inspection - Bearing Installation - End Play Inspection / Adjustment - Crankshaft End Play Adjustment - Counter Balancer Shaft End Play Adjustment - Oil Pump Shaft End Play Adjustment ENGINE REASSEMBLY - Pump Shaft Oil Seal Installation - Crankshaft / Counter Balance / Oil Pump Installation - Crankcase Assembly - Water Pump Mechanical Seal Installation - Water Pump Mechanical Seal Removal (Engine Installed) - One Way Valve Installation - Cam Chain Drive Sprocket Installation - Tensioner Blade Installation - Piston Ring Installation - Piston Installation - Cylinder Installation - Cylinder Head Installation - Cam Chain / Camshaft Installation - Camshaft Timing - Camshaft Timing Illustration - Cam Chain Tensioner Installation - Stator, Flywheel and Starter Drive Installation - Rocker Shaft / Rocker Arm Assembly Installation - Thermostat Installation - Oil Pipes - Engine Installation Notes - Oil Pump Priming Procedure TROUBLESHOOTING - Engine - Spark Plug Fouling - Cooling Troubleshooting CARBURETION INFORMATION - Special Tools - Carburetor Jetting - Mikuni Optional Jet Part Numbers CV CARBURETION SYSTEM - Carburetor Venting Exploded View - Carburetor Venting - BST 34 Carburetor Exploded View (Upper Components) - BST 34 Carburetor Exploded View (Lower Components) - Carburetor Function - Mikuni CV Carb Operation - Starter System (Choke or Enrichment) - Pilot (Idle and Slow) System - Main System - Float System - Pilot Screw - Air/Fuel Mixture Ratio - Jet Needle - Needle Jet - Throttle Opening vs. Fuel Flow CARBURETOR SERVICE - MIKUNI CV - Carburetor Disassembly - Carburetor Cleaning - Carburetor Inspection - Carburetor Assembly - Float Height Adjustment - Needle and Seat Leakage Test - Fuel Level test - Troubleshooting FUEL TANK / FUEL DELIVERY SYSTEM - Fuel Tank / Fuel Delivery System TORQUE SPECIFICATIONS PLASTIC RETAINER INSERTS - Removal / Installation BODY ASSEMBLY - Exploded View SEAT / SIDE PANEL / TANK COVER - Removal / Installation FRONT BUMPER / CAB / FOOTWELL - Front Bumper Removal / Installation - Front Cab Removal - Front Cab Installation - Footwell Removal / Installation REAR RACK / REAR CAB - Rear Rack Removal / Installation - Rear Cab Removal / Installation INSTRUMENT POD - Pod / Key Switch / Choke / Instrument Cluster Removal / Installation STEERING - Steering Post Removal - Steering Post Installation - Handlebar Block Installation Procedure - Tie Rod / Tie Rod End Replacement FRONT SUSPENSION / A-ARM - Exploded View - A-arm Removal - Ball Joint Replacement - A-arm Installation FRONT STRUT - Exploded View - Front Strut Removal - Front Strut Installation REAR CONTROL ARMS - Exploded View - Control Arm Removal / Installation REAR TORSION BAR - Exploded View REAR SHOCKS / SPRINGS - Exploded View - Shock Removal / Installation - Shock / Spring Replacement DECAL REPLACEMENT CVT SYSTEM - Torque Specifications - Clutch Roller Weights - Special Tools - CVT Operation Overview - Starting Clutch Operation - Drive Clutch Operation - Driven Clutch Operation - Engine Braking Clutch - CVT Maintenance / Inspection - CVT Drying - CVT Overheating / Diagnosis - CVT System Disassembly - Drive Belt Inspection - Drive Clutch Service - Driven Clutch Service - Starting Clutch Exploded View (Sportsman 300) - Starting Clutch Exploded View (Sportsman 400 H.O.) TRANSMISSION - Torque Specifications - Shift Linkage Inspection - Gear Selector Removal - Transmission Removal - Transmission Disassembly - Transmission Reassembly - Transmission Installation - Transmission Exploded View GENERAL SPECIFICATIONS - Torque Specifications - Special Tools FRONT BEARING CARRIER - Bearing Carrier Removal - Bearing Removal - Bearing Installation - Bearing Carrier Installation PROPSHAFT SERVICE - Removal - Installation PROPSHAFT U-JOINT SERVICE - Disassembly - Assembly FRONT GEARCASE CENTRALIZED HILLIARD - All Wheel Drive Operation - Centralized Hilliard Exploded View - AWD Diagnosis - Gearcase Removal - Disassembly - Gearcase Reassembly - Installation REAR BEARING CARRIER - Bearing Carrier Inspection - Bearing Carrier Removal - Bearing Removal - Bearing Installation - Bearing Carrier Installation DRIVE SHAFT SERVICE - Front Drive Shaft Removal - Rear Drive Shaft Removal - Drive Shaft / CV Joint Handling Tips - Outer CV Joint / Boot Replacement - Inner Plunging Joint / Boot Replacement - Exploded View - Front Drive Shaft Installation - Rear Drive Shaft Installation SPECIFICATIONS - General Brake Specifications - General Torque Specifications - Special Tools BRAKE SYSTEM SERVICE NOTES BRAKE NOISE TROUBLESHOOTING HYDRAULIC BRAKE SYSTEM OPERATION BRAKE SYSTEM EXPLODED VIEW BRAKE CALIPER - Exploded View HAND MASTER CYLINDER - Exploded View BRAKE BLEEDING - Fluid Replacement - Bleeding Procedure HAND MASTER CYLINDER - Removal - Disassembly - Installation FOOT MASTER CYLINDER - Operation Overview FOOT BRAKE PEDAL - Foot Pedal Removal / Installation - Foot Master Cylinder Removal / Installation BRAKE PADS - Pad Removal - Pad Installation - Brake Burnishing Procedure CALIPER SERVICE - Caliper Removal - Caliper Disassembly - Caliper Inspection - Caliper Reassembly - Caliper Installation BRAKE DISC SERVICE - Disc Inspection - Disc Removal / Replacement TROUBLESHOOTING - Brake Squeal GENERAL INFORMATION - Special Tools - Electrical Service Notes - Component Locations INSTRUMENT CLUSTER - Display Functions - AWD Control System - Instrument Cluster Overview - Rider Information Display - Display Modes - Instrument Cluster Removal ALL WHEEL DRIVE COIL - Operation Overview - Diagnosing System Failures SPEED SENSOR - Vehicle Speed Sensor ELECTRONIC THROTTLE CONTROL (ETC) SWITCH - Electronic Throttle Control (ETC) Switch GEAR SELECTOR SWITCH - Switch Test ETC / REVERSE RPM CONTROL - ETC / Reverse RPM Control System FUSIBLE LINK / FUSES / CIRCUIT BREAKERS - Fusible Link - Fuse and Circuit Breaker Function FAN MOTOR / COOLING SYSTEM THERMAL SWITCHES (400 H.O.) - Cooling System Electrical Break-Out Diagram - Fan Motor Circuit Operation - Fan Motor Circuit Bypass Test - Fan Switch (Thermal Switch) Replacement - Engine Temperature Switch Operation - Engine Temperature Switch Replacement IGNITION SYSTEM - DC/CDI Ignition System Diagram - RPM Limit Modes - Ignition System Troubleshooting - Ignition Coil Testing (Sportsman 300) - Ignition Coil Testing (Sportsman 400 H.O.) - Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter - Ignition Timing - Ignition System Testing LIGHTS - Headlight Adjustment - Headlight Lamp Replacement - Tail / Brake Light Bulb Replacement CHARGING SYSTEM - Charging System Diagram - Charging System Testing Flow Chart - Current Draw - Key Off - Charging System ?Break Even? Test - Charging System Alternator Tests BATTERY SERVICE - Battery Identification CONVENTIONAL BATTERY (SPORTSMAN 300) - Battery Activation - Battery Inspection - Battery Removal / Installation - Conventional Battery Testing - OCV - Open Circuit Voltage Test - Specific Gravity Test - Load Test - Battery Off Season Storage - Charging Procedure (Conventional) LOW MAINTENANCE BATTERY (SPORTSMAN 400 H.O.) - General Battery Information - Battery Removal / Installation - Battery Testing - OCV - Open Circuit Voltage Test - Load Test - Battery Off Season Storage - Charging Procedure (Low Maintenance) STARTER SYSTEM - Starter / Starter Lockout System Diagram - Troubleshooting - Voltage Drop Testing - Starter Motor Removal / Disassembly - Brush Inspection / Replacement - Armature Testing - Starter Reassembly / Installation - Starter Drive - Starter Solenoid Bench Test - Starter Solenoid Operation - Starter Motor Exploded View STARTER SYSTEM TESTING FLOW CHART - Condition: Starter motor fails to turn over the engine.
Polaris Sportsman 300-400 (2009) - Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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