GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL: 2009 SPORTSMAN 300 / 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 DETAILED: 2009 SPORTSMAN 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2009 SPORTSMAN 400 H.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.1
GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification
27 AA
} } }
}
A 0 9 LH
Emissions & Model Option
Year Designation Basic Chassis Designation
Engine Designation
Engine Designation Number ES300PFE .......................................................... Single, Air Cooled, SOHC 4 Stroke, Electric Start EH460PLE ..................................................... Single, Liquid Cooled, SOHC 4 Stroke, Electric Start
Vehicle Identification Number (VIN) World Mfg. ID
Vehicle Identifier
Vehicle Descriptor
4 5 6 7 8 9 10 11 12 13 14 15 16 17 L H 2 7 A * 9 P 0 0 0 0 0 0 Engine
Body Style
}
}
1 2 3 4 X A
Model Year
Individual Serial Number
Plant No Emissions Powertrain Check Digit
* This could be either a number or a letter
Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number is stamped on the center top of the crankcase beneath the cylinder and is also located on the sticker applied to the recoil housing on the right side of engine (see Figure 1-2). Figure 1-2
Figure 1-1
VIN
1.2
Engine Serial Number
GENERAL INFORMATION SPECIFICATIONS
1
MODEL: 2009 SPORTSMAN 300 MODEL NUMBER: . . . . . . . . .A09LH27AX, A09LH27AZ ENGINE MODEL: . . . . . . . . . .ES300PFE012 Category
Dimension
Length
74 in. / 188 cm
Width
42 in. / 107 cm
Height
45.5 in. / 116 cm
Wheel Base
46 in. / 117 cm
Dry Weight
550 lbs. / 250 kg
Gross Vehicle Weight
915 lbs. / 415 kg
Front Rack Capacity
70 lbs. / 31.75 kg
Rear Rack Capacity
100 lbs. / 45 kg
Towing Capacity
750 lbs. / 340 kg
Max. Weight Capacity
365 lbs. / 166 kg
Hitch Tongue Weight
75 lbs. / 34 kg
MODEL: 2009 SPORTSMAN 400 H.O. MODEL NUMBER: . . . . . . . . .A09LH46AQ, A09LH46AX, A09LH46AZ ENGINE MODEL: . . . . . . . . . .EH460PLE020 Category
Dimension
Length
73 in. / 185 cm
Width
44 in. / 112 cm
Height
46 in. / 117 cm
Wheel Base
46 in. / 117 cm
Dry Weight
598 lbs. / 271 kg
Gross Vehicle Weight
963 lbs. / 437 kg
Front Rack Capacity
70 lbs. / 32 kg
Rear Rack Capacity
100 lbs. / 45 kg
Towing Capacity
750 lbs. / 340 kg
Max. Weight Capacity
365 lbs. / 166 kg
Hitch Tongue Weight
75 lbs. / 34 kg
1.3
GENERAL INFORMATION MODEL: 2009 SPORTSMAN 300 MODEL NUMBER:........... A09LH27AX, AZ ENGINE MODEL:............. ES300PFE012 Engine Platform
Fuji 4-cycle, A/C, Single Cyl.
Engine Model Number
ES300PFE012
Engine Displacement
299cc
Number of Cylinders
1
Bore & Stroke (mm)
77.7 x 63 mm
Compression Ratio
9.2:1
Compression Pressure Engine Idle Speed Cooling System
PS-4 Plus / 1.7 qt. (1.6 L)
Exhaust System
Single Pipe - USFS Approved Mikuni BST 34mm
Clutch Type
CVT w/EBS
Belt
3211108 Steering / Suspension
45 / 140
Jet Needle
4HC57-3
Needle Jet
0-5M
Pilot / Air Screw
2.5 Turns Out (Initial setting)
Float Height
13mm from carburetor body
Fuel Delivery
Fuel Pump (Impulse)
Fuel Capacity
4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated
Rear Suspension / Shock
8 in. / 20.3 cm
Ground Clearance
8 in. / 20.3 cm
Shock Preload Adjustment Front / Rear
Voltage Regulator
3-Phase 20 Amp
Head Lights
12V / 37.5 watts
Brake Light
12V / 26.9 watts
Tail Light
12V / 8.26 watts
Ignition System
DC / CDI
Ignition Timing
10° ± 2° BTDC @ 1500 RPM 30° ± 2° BTDC @ 5000 RPM
Spark plug / Gap
NGK CR8E / .031 in. (.8 mm)
Starting Indicator Panel
1.4
Cam Adjustable 62.5 in. (159 cm) unloaded
Toe Out
0-1/16 in. (0-.159 mm) Wheels / Brakes
Front Wheel Size Front Tire Model / Size
12x5 Maxxis AT / 22 x 7-12
Rear Wheel Size Rear Tire Model / Size
12x8 Maxxis AT / 22 x 10-12
Tire Air Pressure - F / R
5 psi (34.5 kPa) Single Control Hydraulic Disc
Brakes - Front & Rear Brake Fluid
Polaris DOT 4 Brake Fluid
JETTING CHART AMBIENT TEMPERATURE
250 watt @ 6000 RPM
Circuit Breakers
IRS / Progressive Rate
Rear Travel
Electrical Alternator Output
Battery / Model / AH
MacPherson Strut 7 in. / 17.8 cm
140
Pilot Jet / Pilot Air Jet
Fuel Requirement (Octane)
Front Output Fwd 5.17:1 / Rev 4.79:1 Rear Output Fwd 15.18:1 / Rev 14.05:1
Turning Radius
Carburetion Main Jet
Gear Ratio :
1400 RPM
Oil Requirements
Polaris Premium AGL / 20.3 oz. (592 ml)
Front Gearcase Fluid Type Polaris Demand Drive Hub / Fluid Capacity Fluid / 5 oz. (148 ml)
Front Travel
Wet Sump
Carburetor model
Transmission Fluid Type / Fluid Capacity
Front Suspension / Shock
None
Lubrication
In-Line F-N-R
120-140 psi Air / Oil Cooled
Overheat Warning
Drivetrain Transmission Type
ALTITUDE Meters (Feet) 0-900 (0-3000)
Electric / Recoil Back-up LCD / Indicator lights
Above +40° F Above +5° C
145
140
900-1800 (3000-6000)
Same main jet / Remove 2 air box plugs
1800-2700 (6000-9000)
Same main jet / Remove 4 air box plugs
Above 2700 (Above 9000)
Same main jet / Remove 6 air box plugs Move jet needle clip to position #2
CLUTCH CHART ALTITUDE
Yuasa / YB14-B2 / 14 AH 15A - Accessory / 15A - Main Harness
Below 40° F Below 5° C
Meters (Feet)
SHIFT WEIGHT
# INSTALLED
0-1500 (0-5000)
13 g 5412988
8
1500-3000 (5000 - 10000)
10 g 5412986
8
3000 + (10000 +)
10 g 5412986
6*
*Note: Remove opposite rollers to retain proper clutch balance
GENERAL INFORMATION MODEL: 2009 SPORTSMAN 400 H.O. MODEL NUMBER: .... A09LH46AQ, AX, AZ ENGINE MODEL: ...... EH460PLE020 Engine Platform
Fuji 4-cycle, L/C, Single Cyl.
Engine Model Number
EH460PLE020
Engine Displacement
455cc
Number of Cylinders
1
Bore & Stroke (mm)
87.9 x 75 mm
Compression Ratio
10.1:1
Compression Pressure
50-90 psi
Engine Idle Speed
1375 RPM
Cooling System / Cap. Overheat Warning
Liquid / 2.2 qt. (2 L) LCD / Red Indicator Light
Lubrication
Dry Sump
Oil Requirements
PS-4 Plus / 2 qt. (1.9 L)
Exhaust System
Single Pipe - USFS Approved Mikuni BST 34mm
Main Jet
42.5 / 160
Jet Needle
4IB33-3
Needle Jet
P-6M
Pilot / Air Screw
2.75 Turns Out (Initial setting)
Float Height
13mm from carburetor body
Fuel Delivery
Fuel Pump (Impulse)
Fuel Capacity / Fuel Requirement (Octane)
Transmission Fluid Type / Fluid Capacity
4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated
Gear Ratio :
Front Output Fwd 5.17:1 / Rev 4.79:1 Rear Output Fwd 15.18:1 / Rev 14.05:1
Clutch Type
CVT w/EBS
Belt
3211129 Steering / Suspension
Front Suspension / Shock
7 in. / 17.8 cm
Rear Suspension / Shock
IRS / Progressive Rate
Rear Travel
8 in. / 20.3 cm
Ground Clearance
9 in. / 22.9 cm
Shock Preload Adjustment Front / Rear
Cam Adjustable 69 in. (175 cm) unloaded
Toe Out
0-1/16 in. (0-.159 mm) Wheels / Brakes
Front Wheel Size Front Tire Model / Size
12x5 Titan 489 / 24 x 8-12
Rear Wheel Size Rear Tire Model / Size
12x8 Titan 489 / 24 x 11-12
Tire Air Pressure - F / R
5 psi (34.5 kPa) Single Control Hydraulic Disc
Brakes - Front & Rear Brake Fluid
Polaris DOT 4 Brake Fluid
JETTING CHART AMBIENT TEMPERATURE
Alternator Output
250 watt @ 6000 RPM
Voltage Regulator
3-Phase 20 Amp
Head Lights
12V / H-35 watts, L-35 watts
Brake Light
12V / 26.9 watts
Tail Light
12V / 8.26 watts
Ignition System
DC / CDI
Ignition Timing
14° ± 2° BTDC @ 1500 RPM 30° ± 2° BTDC @ 5000 RPM
Spark plug / Gap
NGK BKR6E / .035 in. (.9 mm)
Battery / Model / AH
Yuasa / YTX14AH-BS / 12 AH
Circuit Breakers
10A - Accessory / 10A - Fan / 15A - Main Harness
Indicator Panel
MacPherson Strut
Front Travel
Electrical
Starting
Polaris Premium AGL / 20.3 oz. (592 ml)
Front Gearcase Fluid Type Polaris Demand Drive Hub / Fluid Capacity Fluid / 5 oz. (148 ml)
157.5
Pilot Jet / Pilot Air Jet
1
In-Line F-N-R
Turning Radius
Carburetion Carburetor model
Drivetrain Transmission Type
ALTITUDE
Meters (Feet)
Below 40° F Below 5° C
Above +40° F Above +5° C
0-1800 (0-6000)
162.5
157.5
1800-3700 (6000-12000)
150
145
CLUTCH CHART ALTITUDE
Meters (Feet)
SHIFT WEIGHT
# INSTALLED
0-1500 (0-5000)
19.5 g 5413447
8
1500-3000 (5000 - 10000)
17 g 5412975
8
3000 + (10000 +)
16 g 5412991
8
Electric / Recoil Back-up LCD / Indicator lights
1.5
GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers YEAR
MODEL
MODEL NO.
OWNER’S MANUAL PN
PARTS MANUAL PN
2009
SPORTSMAN 300
A09LH27AX, AZ
9921818
9921819
2009
SPORTSMAN 400 H.O.
A09LH46AQ, AX, AZ
9921822
9921823
NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
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, replacement of the ignition switch assembly is necessary.
Series #
Part Number
20
4010278
21
4010278
22
4010321
23
4010321
27
4010321
28
4010321
31
4110141
32
4110148
67
4010278
68
4010278
Special Tools Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/.
1.6
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS
1
Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to the exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.
Bolt Size
Threads/In
#10 #10
-
Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) 24. . . . . . . . . . . . . . . . .27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . .60 (6.9) 32. . . . . . . . . . . . . . . . .31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . .68 (7.8)
1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2
-
Torque ft. lbs. (Nm)* 20. . . . . . . . . . . . . . . . .5 (7) . . . . . . . . . . . 8 (11) . . . . . . . . . .12 (16) 28. . . . . . . . . . . . . . . . .6 (8) . . . . . . . . . . . 10 (14) . . . . . . . . .14 (19) 18. . . . . . . . . . . . . . . . .11(15) . . . . . . . . . . 17 (23) . . . . . . . . .25 (35) 24. . . . . . . . . . . . . . . . .12(16) . . . . . . . . . . 19 (26) . . . . . . . . .29 (40) 16. . . . . . . . . . . . . . . . .20(27) . . . . . . . . . . 30 (40) . . . . . . . . .45 (62) 24. . . . . . . . . . . . . . . . .23(32) . . . . . . . . . . 35 (48) . . . . . . . . .50 (69) 14. . . . . . . . . . . . . . . . .30(40) . . . . . . . . . . 50 (69) . . . . . . . . .70 (97) 20. . . . . . . . . . . . . . . . .35(48) . . . . . . . . . . 55 (76) . . . . . . . . .80 (110) 13. . . . . . . . . . . . . . . . .50(69) . . . . . . . . . . 75 (104) . . . . . . . .110 (152) 20. . . . . . . . . . . . . . . . .55(76) . . . . . . . . . . 90 (124) . . . . . . . .120 (166)
Metric / Torque 6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25
14-18 ft.lbs . . . . 10 x 1.25
26-30 ft.lbs.
1.7
GENERAL INFORMATION SAE Tap Drill Sizes Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64
Decimal Equivalents Thread Size / Drill Size 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4
1/64 3/64 5/64 7/64 9/64 11/64 13/64 15/64 17/64 19/64 21/64 23/64 25/64 27/64 29/64 31/64 33/64 35/64 37/64 39/64
Metric Tap Drill Sizes Tap Size
Drill Size
3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11x1.50 12x1.50 12x1.75
#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32
1.8
41/64 Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406
Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32
43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64
................. 1/32 . . . . . . . . . . . . . ................. 1/16 . . . . . . . . . . . . . ................. 3/32 . . . . . . . . . . . . . ................. 1/8 . . . . . . . .1250 ................. 5/32 . . . . . . . . . . . . . ................. 3/16 . . . . . . . . . . . . . ................. 7/32 . . . . . . . . . . . . . ................. 1/4 . . . . . . . .25 ................. 9/32 . . . . . . . . . . . . . ................. 5/16 . . . . . . . . . . . . . ................. 11/32 . . . . . . . . . . . . ................. 3/8 . . . . . . . .375 ................. 13/32 . . . . . . . . . . . . ................. 7/16 . . . . . . . . . . . . . ................. 15/32 . . . . . . . . . . . . ................. 1/2 . . . . . . . .5 ..... ................. 17/32 . . . . . . . . . . . . ................. 9/16 . . . . . . . . . . . . . ................. 19/32 . . . . . . . . . . . . ................. 5/8 . . . . . . . .625 ... ................. 21/32 . . . . . . . . . . . . ................. 11/16 . . . . . . . . . . . . ................. 23/32 . . . . . . . . . . . . ................. 3/4 . . . . . . . .75 ................. 25/32 . . . . . . . . . . . . ................. 13/16 . . . . . . . . . . . . ................. 27/32 . . . . . . . . . . . . ................. 7/8 . . . . . . . .875 ................. 29/32 . . . . . . . . . . . . ................. 15/16 . . . . . . . . . . . . ................. 31/32 . . . . . . . . . . . . ................. 1 . . . . . . . . . 1.0
.0156 .0312. . . 1 mm= .0394" .0469 .0625 .0781. . . 2 mm = .0787" .0938 .1094. . . 3 mm =.1181" .1406 .1563. . . 4 mm = .1575" .1719 .1875. . . 5mm= .1969" .2031 .2188 .2344. . . 6 mm = .2362" .2656. . . 7 mm = .2756" .2813 .2969 .3125. . . 8mm= .3150" .3281 .3438. . . 9 mm = .3543" .3594 .3906. . . 10 mm = .3937" .4063 .4219. . . 11 mm =.4331" .4375 .4531 .4688. . . 12 mm = .4724" .4844 . . . . . . . 13mm = .5118" .5156 .5313 .5469. . . 14 mm = .5512" .5625 .5781. . . 15 mm = .5906" .5938 .6094 . . . . . . . 16mm=. 6299" .6406 .6563. . . 17 mm =.6693" .6719 .6875 .7031. . . 18 mm = .7087" .7188 .7344. . . 19 mm = .7480" .7656 .7813. . . 20 mm = .7874" .7969 .8125. . . 21 mm =.8268" .8281 .8438 .8594. . . 22 mm = .8661" .8906. . . 23 mm = .9055" .9063 .9219 .9375. . . 24 mm = .9449" .9531 .9688. . . 25 mm = .9843" .9844
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GENERAL INFORMATION Conversion Table Unit of Measure
Multiplied by
ft. lbs.
x 12
= in. lbs.
in. lbs.
x .0833
= ft. lbs.
ft. lbs.
x 1.356
= Nm
in. lbs.
x .0115
= kg-m
Nm
x .7376
= ft. lbs.
kg-m
x 7.233
= ft. lbs.
kg-m
x 86.796
= in. lbs.
kg-m
x 10
= Nm
in.
x 25.4
=mm
mm
x .03937
= in.
in.
x 2.54
= cm
mile (mi.)
x 1.6
= km
km
x .6214
= mile (mi.)
Ounces (oz.)
x 28.35
= Grams (g)
Fluid Ounces (fl. oz.)
x 29.57
= Cubic Centimeters (cc)
Cubic Centimeters (cc)
x .03381
= Fluid Ounces (fl. oz.)
Grams (g)
x 0.035
= Ounces (oz.)
lb.
x .454
= kg
kg
x 2.2046
= lb.
Cubic inches (cu. in)
x 16.387
= Cubic centimeters (cc)
Cubic centimeters (cc)
x 0.061
= Cubic inches (cu. in)
Imperial pints (Imp pt.)
x 0.568
= Liters (l)
Liters (l)
x 1.76
= Imperial pints (Imp pt.)
Imperial quarts (Imp qt.)
x 1.137
= Liters (l)
Liters (l)
x 0.88
= Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.)
x 1.201
= US quarts (US qt.)
US quarts (US qt.)
x 0.833
= Imperial quarts (Imp qt.)
US quarts (US qt.)
x 0.946
= Liters (l)
Liters (l)
x 1.057
= US quarts (US qt.)
US gallons (US gal)
x 3.785
=Liters (l)
Liters (l)
x 0.264
= US gallons (US gal)
Pounds - force per square inch (psi)
x 6.895
= Kilopascals (kPa)
Kilopascals (kPa)
x 0.145
= Pounds - force per square inch (psi)
Kilopascals (kPa)
x 0.01
= Kilograms - force per square cm
Kilograms - force per square cm
x 98.1
= Kilopascals (kPa)
π(3.14)xR x H (height) 2
1
Converts to
= Cylinder Volume
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C
1.9
GENERAL INFORMATION Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.
1.10
MAINTENANCE
CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.8
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 HANDLEBAR COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 THROTTLE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 ELECTRONIC THROTTLE CONTROL SWITCH (ETC) /THROTTLE CABLE ADJUSTMENT2.12 CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PILOT SCREW LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PILOT SCREW AND IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR FILTER / PRE-FILTER SERVICE (300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR FILTER / PRE-FILTER SERVICE (400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL AND FILTER CHANGE (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 ENGINE OIL AND FILTER CHANGE (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . 2.19 OIL PUMP PRIMING PROCEDURE (SPORTSMAN 400 H.O.). . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER FILTER (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 ENGINE BREATHER FILTER (SPORTSMAN 400 H.O.). . . . . . . . . . . . . . . . . . . . . . . . 2.21 VALVE CLEARANCE (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 VALVE CLEARANCE (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 EXHAUST SILENCER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 ENGINE MOUNT FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TRANSMISSION / FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.1
MAINTENANCE COOLING SYSTEM (400 H.O.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
CVT / FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BATTERY REMOVAL (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY INSTALLATION (SPORTSMAN 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY REMOVAL (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY INSTALLATION (SPORTSMAN 400 H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TOE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 BRAKE PEDAL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
2.2
MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation 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.
Break-In Period The break-in period consists of the first 20 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. • Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle. • Pull only light loads. • Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist. • Change both the engine oil and filter after 20 hours or one month. • See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance: = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
2.3
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