2005 Polaris SPORTSMAN 400 Parts Manual - PDF DOWNLOAD

PARTS MANUAL PN 9919413 and MICROFICHE PN 9919414 7/04

SPORTSMAN 400 Model #A05MH42AB Model #A05MH42AG Model #A05MH42AH E 2004 Polaris Sales Inc.

TABLE OF CONTENTS SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

A

A-- ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1

B

BRAKE LINES, FRONT . . . . . . . . . . . . . . . . B6 BUMPER MOUNTING . . . . . . . . . . . . . . . . . A7-8

C

CALIPER, REAR . . . . . . . . . . . . . . . . . . . . .

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROLS - THROTTLE ASM./CABLE . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT and PISTON . . . . . . . . . . . . .

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .

D

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . .

DRIVE SHAFT, REAR . . . . . . . . . . . . . . . . .

DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .

B7 D7-8 C9 B4 B9 A11 D4 D6 D5 A10 C7 B10 B11 C8

E

ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C13 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A12

F

FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . .

FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .

FRONT HOUSING . . . . . . . . . . . . . . . . . . . .

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

B8 A5 D3 D11 B2

G

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C6 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . D1-2 HANDLEBAR . . .

H

. . . . . . . . . . . . . . . . . . . C1-2

H

HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2 HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . C3

I

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D9

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . E2 MASTER CYLINDER, REAR . . . . . . . . . . . . B8

O

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D13 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B3

P

PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B12

R

RACK MOUNTING FRONT . . . . . . . . . . . . .

REAR CAB and SEAT . . . . . . . . . . . . . . . . .

REAR RACK MOUNTING . . . . . . . . . . . . . . .

REAR SUSPENSION . . . . . . . . . . . . . . . . . .

REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .

RECOIL STARTER . . . . . . . . . . . . . . . . . . . .

S

STARTING MOTOR . . . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . . . . .

STORAGE BOX, REAR . . . . . . . . . . . . . . . .

STORAGE, FRONT . . . . . . . . . . . . . . . . . . .

STRUT MOUNTING . . . . . . . . . . . . . . . . . . .

STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . .

A8 A3 -4 A6 C11-12 C10 D14 E1 C5 A9 A7-8 C4 B13

T

TAILLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . C3 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 TRANSMISSION MOUNTING . . . . . . . . . . . . C14

W

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D10 WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . . B14 WORKLAMPS . . . . . . . . . . . . . . . . . . . . . . . C3

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

REAR CAB and SEAT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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Rear Cab Foil View From Bottom

A3

REAR CAB and SEAT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

Qty. Description

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2 2 3 3 2 1 4 2 1 1 1 1 14 1 1

13 14 15 16 17 18 19 20 21 22 23

8 8 2 1 1 1 2 2 1 1 1 1 1 2

7512095 7555798 7512026 7556034 7511930 5246076 7555792 7541925 5435363-400 5435363-293 5435363-341 10 7170911 11 7661855 12 5435354-070 5435355-070

Screw Washer Screw Washer Bolt Retainer, Seat Latch Washer Nut, Nylok Cab, Rear, Camo Green Metallic (AH) Cab, Rear, Indy Red (AB) Cab, Rear, Sonic Blue (AG) Decal, Hitch Rivet Footwell, Black, LH Footwell, Black, RH

7517230 7542122 5812703 5812702 5812701 1014536-067 7621403 5211033 7041370 1040387 2683433-070 2683434-070 24 7079902 25 5412623

Screw Nut, Nylok Foil, Rear Cab, Front, Top Foil, Rear, Cab, Front, Bottom Foil, Cab, Rear Frame, Main, Black Rivet Bracket, Lever Retainer Spring, Latch Latch, Seat Asm., Seat, Black Covering, Seat, Black Decal, Carb/Filter Information Grommet 7/04

A4

FRONT CAB SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 5435352-400 5435352-293 5435352-341 2 2632864-400 2632864-293 2632864-341 3 7670057 4 7517219 5 5435353-177 2632936-177 5435353-070 2632936-070

Qty. Description

1 1 1 1 1 1 2 2 1 1 1 1

Cover, Front, Camo Grn Met (AH) Cover, Front, Indy Red (AB) Cover, Front, Sonic Blue (AG) Cab, Front, Camo Green Met (AH) Cab, Front, Indy Red (AB) Cab, Front, Sonic Blue (AG) Nut, U-Type Speed Screw Panel, Side, LH, Black (AH)(AG) Asm., Panel/Foil, RH, Black (AH)(AG) Panel, Side, LH, Black (AB) Asm., Panel/Foil, RH, Black (AB)

Ref. Part No.

6 7 8 9 10 11 12 13 14

5812615 7080756 7517386 5248100 7546601 5246872 7661855 7512026 7556034

Qty. Description

1 1 4 1 2 1 2 8 4

Foil, Side Panel, RH Clip Screw Guard, Splash, RH Nut, Nylok Guard, Splash, LH/Pump Mount Rivet Screw Washer 7/04

A5

REAR RACK MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 1 E 2004 Polaris Sales Inc. 17

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Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

7517230 7517983 5248469-418 7518375 2632867-070 7518213 5435959 7555843 7542324

Qty. Description

4 2 1 2 1 2 2 2 2

Screw Screw Channel, Rear Screw Asm., Rack, Rear (Incl. Warning Decal) Screw Spacer Washer, Flat Nut, Nylok

Ref. Part No.

10 11 12 13 14

5248471-418 5334092 1014668-067 7518341 -------

15 7542343 16 7542153 17 7517685

Qty. Description

1 2 1 4 1

Channel, Front Spacer Support, Rear Rack Bolt, Flange Bracket, Silencer, Frame (See Exhaust System Pg. A12, Ref. 6) 4 Nut, Nylok, Flange 4 Nut, Nylok 2 Screw 7/04

A6

FRONT STORAGE and BUMPER MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH E 2004 Polaris Sales Inc.

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A7

19

FRONT STORAGE and BUMPER MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 7515399 2 1014591-067 1014592-067 3 7518341 4 5810467 5 7542343 6 1014636-067 7 5435629 8 5812778 9 7081145 7081125 10 7512076 11 5334257 12 7661855 13 5434314 5434315 14 5412504 15 5435046 16 5247507-067 17 7518046

Qty. Description

6 1 1 2 1 8 1 1 1 1 1 4 2 6 1 1 4 1 1 4

Screw Support, Rack, LH Support, Rack, RH Screw, Flange Plug, Frame Nut, Nylok, Flange Guard, Brush Cover, Radiator Seal, Radiator Cover Latch, LH Latch, RH Screw Latch, Wire Rivet Shield, Side, Radiator, LH Shield, Side, Radiator, RH Grommet Cover, Radiator Grill, Brush Guard Screw

Ref. Part No.

Qty. Description

18 5435701 5435702 19 5435357-070 20 7518383 21 7518382 22 7556341 23 2632865-070

1 1 1 2 4 4 1

24 25 26 27 28 29 30 31 32 33 34 35

1 3 2 4 4 1 1 2 8 8 2 1

1202838 5412352 5435628 7555960 7517208 5521693 5435362-070 5247653-418 7542122 7518427 5134576 5521706

Cover, Bumper, LH Cover, Bumper, RH Panel, Bumper, Front Screw Screw Washer, Flat Asm., Bumper, Front, Black (Incl. Warning Decal) Asm., Box, Lower, Front Plug Cover, Strut Washer, Flat Screw, Flange Seal Cover, Box, Front Channel, Lid, Front Nut, Nylok Screw Pin, Hinge, Front Seal, Lid/Bumper 7/04

A8

REAR STORAGE BOX SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

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5435605 7081205 5435368 5521694

Qty. Description

1 1 1 1

Ref. Part No.

Box, Upper Latch Cover, Tool Box Seal

5 6 7 8

5810455 5435630 5412352 7661855

Qty. Description

2 1 1 2

Pad, Rack Mount Box, Lower Plug Rivet 7/04

A9

DECALS SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 2

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E 2004 Polaris Sales Inc.

RH

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LH

8

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

Qty. Description

1 2 3 4

2 1 2 1 1 1 1 1 1 1 1

9 10 11 12 13

1 1 1 1 1 1 1 1 1 1

5 6 7 8

7172689 7173013 7172572 7172707 7172708 7172559 7172704 7172710 7079780 7172687 7172688

Decal, Reflector, Red Urocal, 50th Anniversary Decal, Warning Front and Rear Rack Decal, Rear Cab, “AWD”, LH Decal, Rear Cab, “AWD”, RH Decal, Age Warning, 16 ATV Decal, “SPORTSMAN”, LH Decal, “SPORTSMAN”, RH Decal, Warning, AWD Switch, White Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH

14 15 16 17

7172562 7078465 7079672 7172564 7172705 7172706 7172560 7172561 7172566 7172748

Decal, Drain Recoil Logo, Polaris Star Decal, Foot Brake Decal, Warning, Override, AWD Decal, Tankside, “400”, LH Decal, Tankside, “400”, RH Decal, Warning, General, CPSC Decal, Discretional Warning Decal, Passenger Warning Decal, Tire Pressure/Load 7/04

A10

COOLING SYSTEM SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 8 1

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6 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

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7517975 2410383 1240044 5412402 7512084 7080826 5412405 7080696 5412404 5521550 7080851 7517386 7080138 7080492

Qty. Description

4 1 1 1 4 4 1 2 1 2 1 3 1 1

Screw Asm., Fan and Motor Cap, Pressure Neck, Filler Screw Clamp Hose, Filler Neck Clamp Hose, Engine, Lower Guard, Hose, Plastic Clamp, Hose Screw Cable Tie Cable Tie

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27

5247047-067 5410584 7515179 1240152 5411975 8450003-1525 7052065 5431673 5433774 5810279 5430743 5412403 5246754-067

Qty. Description

1 2 2 1 2 1 1 1 1 1 1 1 1

Bracket, Radiator, Lower Bushing, Mount, Lower Screw Radiator Asm., Grommet and Insert Line, Fuel Fitting, Barbed, 90 Degree Tank, Surge Plug, Cap Gasket, Overflow Cap Cap, Overflow, Drilled Hose, Engine, Upper Bracket, Radiator, Lower 7/04

A11

EXHAUST SYSTEM SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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13 14

18 17 12

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Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

7542324 7555716 5410436 7555863 5010192 5241663 5412508 7515316 1261042-029

Qty. Description

3 3 3 3 3 1 3 3 1

Nut, Nylok Washer, Flat Washer, Rubber Washer Bushing Bracket, Silencer, Frame Dampener, Vibration Bolt, Carriage Silencer, Exhaust

Ref. Part No.

10 11 12 13 14 15 16 17 18

7512666 7556230 7041804 7515197 7555935 5248727 1261246-029 5243518 1261043-029

Qty. Description

1 1 4 4 4 2 1 2 1

Bolt Washer, Clean Out Spring, Exhaust Screw Washer Shield, Heat, Exhaust Pipe, Exhaust Seal, Exhaust Manifold 9/04

A12

ENGINE MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 32

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A13

15

ENGINE MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

Qty. Description

1 2 3 4 5 6 7 8 9

8450003-1525 7052075 5247154 3084205 7542105 7558203 3110050 7542143 -------

AR 1 1 2 2 2 2 2 1

21 5241150 22 7518415 23 3087023

10 11 12 13 14 15 16 17 18 19 20

8360009-600 7051011 5412487 7080511 4010895 7547263 5224658-067 3110046 7555815 7555797 3110044

AR 1 1 2 1 8 1 2 2 2 2

1 Mount, Engine, Front 2 Screw 1 Engine, Short Block (EH42PLE053) NOTE: The Short Block assembly contains a crankcase assembly, cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization is required for warranty consideration.

1 Bushing 1 Washer, Interlock 1 Bolt 1 Washer, Flat 1 Asm., Bolt and Washer 1 Mount, Engine, Top 2 Washer, Spring Lock 2 Bolt 8 Clamp, Hose, Red AR Hose, Fuel 1 Filter AR Line, Fuel

Line, Fuel Fitting, Tee Strap, Carburetor Mount Screw and Washer Nut Washer Mount, Carb Insert Asm., Carburetor (See Carburetor Pg. D8, Ref. 9) Line, Fuel Valve, Check Vent Boot, Clutch Intake Clamp, Narrow Band Cable, Black, Frame/Engine Nut, Flange Lock Strap, Frame Support Mount, Rubber, Front Washer Washer, Flat Mount, Rubber, Top

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5430261 7575202 7512566 5210748 3082038 5241453 7552901 7512315 7080003 8450103 2530009 8450040-600

7/04

A14

AIR BOX SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 8 6 E 2004 Polaris Sales Inc.

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24 23 22

17

20

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18

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

Qty. Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 1 1 1 1 6 1 4 1 1 1 4 AR 1

15 16 17 18 19 20 21 22 23 24 25 26 27

1 1 1 1 1 1 1 1 AR 1 1 2 2

5811633 7080595 7080413 5811482 5432868 5242044 5411422 7517317 5433293 5811626 5433387 7080699 8450073-600 7080913

Filter, Precleaner Sleeve Filter, Air Intake Clamp, Narrow Band Seal, Air Box Cover Cover, Air Box Clip, Air Box Gasket, Intake Screw Duct, Air Inlet Seal, Foam Box, Air Clamp, Hose Line, Breather P-Clamp

5411858 7080694 2530029 7080511 5412283 5433847 5411668 5432377 8450059-150 7080650 5811650 7558301 7515179

Hose, Breather Clamp Filter, Breather Clamp Boot, Carburetor Sleeve Line, Breather Plug, Trap Line, Fuel Clamp, Hose Foil, Air Box Washer, Flat Screw 7/04

B1

FUEL TANK SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 9 E 2004 Polaris Sales Inc.

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7

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22 21 20

17

18 19

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

Qty. Description

1 7517685 2 5247184 5247185 3 5812265 4 8360009-600 5 5431053 6 5433687 7 5812123 8 7052159 9 5432559 10 7517505 11 5432733

2 1 1 1 AR 1 1 1 1 1 1 1

12 13 14 15 16 17 18 19 20 21 22

4 AR 1 5 1 1 1 2 1 1 1

Screw Bracket, Fuel Cover Mount, LH Bracket, Fuel Cover Mount, RH Seal, Foam Line, Fuel Vent, Tank Cap, Gas Tank Gasket, Fuel Cap Valve, On/Off Knob, Fuel Valve Screw Nut, Fuel Valve

7080003 8450103 7080492 7518257 2410554 5810858 7052363 7515136 5812005 5812004 2520403

Clamp, Hose, Red Hose, Fuel Cable Tie Screw Sender, Fuel Gasket Fitting, Fuel, Single Outlet Screw Foil, Tank Foil, Tank Asm., Fuel Tank w/Sender (Incl. 15-21) 7/04

B2

OIL TANK SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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15 12

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17 5 6 15 7 8

9

14 11

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12

13

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

5411668 7080699 5434574 8450073-34 7080474 8450096-25 7512017 7080693 7081026

Qty. Description

1 2 1 1 2 1 1 1 1

Line, Breather Clamp Dipstick Hose, Breather Clamp Line Screw Clamp Clamp

Ref. Part No.

10 11 12 13 14 15 16 17 18

7052326 5412507 5333204 5410828 7512242 7558301 7051524 5850135 1261176

Qty. Description

1 1 2 2 2 2 1 1 1

Screen, Oil Filter, 90 Degree Grommet Bushing, Mounting Grommet Screw Washer, Flat Plug Washer, Nylon Tank, Oil 7/04

B3

CONTROLS SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc. 1 2 3

4 6

5

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

2010238 1 7517899 2 2202725 3 2201836

Qty. Description

Ref. Part No.

1 Asm., Master Cylinder 2 Screw, Torx 1 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 1 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring)

4 2201833 5 2202410 6 2201835

Qty. Description

1 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 1 Kit, Piston (Incl. Piston, Seals, Boot, Spring) 1 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 7/04

B4

FRONT BRAKE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

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2

3 E 2004 Polaris Sales Inc.

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4

5 6

7

8

10

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4

1910841 1910842 7515489 5134639 5134640 1930642 5410494 1930665

Qty. Description

1 1 1 1 1 1 1 1

Asm., Brake Caliper, LH (Incl. 1-7,9,10) Asm., Brake Caliper, RH (Incl. 1-7,9,10) Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH Kit, Front Brake Boot Boot, Pin Seal Kit, Piston and Seal (Incl. 5-7)

Ref. Part No.

5 6 7 8 9 10 11

5410780 5410779 5132294 2202412 1910411 5410495 7080352

Qty. Description

1 1 1 1 1 1 1

Ring, Molded Square (.103 x .134) Ring, Molded Square (.094) Piston, Brake, Long Kit, Front Brake Pad Mount, Caliper Boot, Bushing Screw, Bleeder 7/04

B5

FRONT BRAKE LINES SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

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3

3 4

10 9 8

5 6 2

7 2

1

1

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5

5410988 1910499 1910883 7052292 1910839

Qty. Description

6 3 1 1 1

Seal Bolt, Banjo Line, Brake, Stainless Steel Fitting, Cross Line, Brake, Right Front, SS

Ref. Part No.

6 7 8 9 10

8360031-34 7080138 1910838 7512024 4110164

Qty. Description

1 4 1 2 1

Conduit Cable Tie Line, Brake, Left Front, SS Screw Switch 7/04

B6

REAR CALIPER SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1 2

E 2004 Polaris Sales Inc.

1 3

4, 5 3

5 5 3 4, 5 6 7

1, 3

1 1, 3, 7 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1910690 1 2201873 2 1910538 3 2201870

Qty. Description

1 1 2 1

Ref. Part No.

Asm., Caliper Kit, Anvil Body Fitting, Bleed, Compact Kit, Slide Bolt

4 5 6 7

2201872 2201869 1910529 2202414

Qty. Description

1 1 1 1

Kit, Seal Kit, Piston and Seal Bracket, Caliper Kit, Brake Pad 3/04

B7

REAR MASTER CYLINDER/FOOT PEDAL SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

6

E 2004 Polaris Sales Inc.

5 3

11

12

7

4

13 2 14

10 8 1 2

9

4

25 27

26

15 16

18

17

20

22 23

21

21

20

19

24

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

2202708 2202660 1910690 5410988 1910760 1910499 7670126 7517756 7080138 7512024 7080499 7080003 7542153 1930854 7512240

Qty. Description

1 1 1 4 1 2 1 1 3 1 1 2 1 1 1

Kit, Brake Line, Rear (Incl. 16) Kit, Brake Line, Rear (Incl. 3) Asm., Caliper Seal Line, Brake, Caliper, Rear Bolt, Banjo Clip, Retaining Screw Cable Tie Screw Clamp, Cable Clamp, Hose Nut Reservoir, Brake, Rear Screw

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26 27

1910315 7042291 1910765 1910790 7542122 7041750 7555919 5433189 7512247 1910814-067 7661401 7512365 7552901 7558402

Qty. Description

1 1 1 1 2 1 2 2 2 1 1 2 2 2

Hose, Reservoir Spring, Park Lockout Line, Rear Brake Master Cylinder, Brake, Rear Nut, Nylok Spring Washer Bushing, Pivot, Pedal Screw Pedal, Brake Pin, Cotter Screw Washer, Spring Lock Washer, Flat 7/04

B8

CONTROLS - THROTTLE ASM./CABLE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc.

2 3

4 5

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4

5410193 5434113 5411439 7081181

Qty. Description

1 1 1 1

Ref. Part No.

O-Ring Cover O-Ring Cable, Throttle

5 2010230 2010250 6 2010191

Qty. Description

1 Asm., Throttle Control, AWD (Incl. 6)(If built before 10/04/04) 1 Asm., Throttle Control, AWD (Incl. 6)(If built after 10/04/04) 1 Asm., Throttle Clamp 7/04

B9

FRONT DRIVE SHAFT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc. 2

3

4

5

1

3 6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1380234 1 7670092 2 1590395 3 7710557

Qty. Description

2 2 2 2

Asm., Drive Shaft, Front Circlip Joint (CV, Inner) Circlip

Ref. Part No.

4 2202826 5 2201015 6 1590396

Qty. Description

2 Kit, Boot (Inner)(Incl. Clamps and Grease) 1 Kit, Boot (Outer)(Incl. Clamps and Grease) 1 Joint, CV (Outer) 7/04

B10

REAR DRIVE SHAFT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc. 1

2

3

4

4

5

10

6

2

7

8

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1380240 1 2 3 4

1590325 1350044 1350046 1350045

Qty. Description

2 Asm., Drive Shaft, Rear (Incl. 1-8)(If built after 11/24/03) 1 CV Joint 2 Clamp, Large 1 Grease, 30g 2 Boot

Ref. Part No.

5 6 7 8 9 10

1350043 1350047 1590281 1350042 2201374 2201373

Qty. Description

2 1 1 1 1 1

Clamp, Small Grease, 50g Joint, Plunging Ring, Spring Kit, Boot (Gear Side) Kit, Boot (Wheel Side) 7/04

B11

PROP SHAFT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

3

E 2004 Polaris Sales Inc.

4

5

2

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1380233 1 3260133 2 2202015 3 3260131

Qty. Description

1 1 2 1

Asm., Shaft, Prop, Front Yoke, Gear Case, Front Kit, Cross and Bearing Yoke, Prop Shaft, Transmission

Ref. Part No.

4 7080424 5 5411092 6 7661913

Qty. Description

1 Fitting, Lubrication 1 O-Ring 1 Pin, Spring 7/04

B12

FRONT STRUT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

16

5

1 2

6

3

7

22

4

8 21

17

11

20

19

18

9

16

11

13

14

15 11 10 12

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12

7547104 7555749 5810291 5432872 5132062 5432871 5243364 7042299-067 5412665 7515339 7558402 5134154 5134155

Qty. Description

2 2 2 2 2 2 2 2 2 4 10 1 1

Nut, Nylok Washer Spacer, Rubber Ball, Pivot, Top Spacer Ball, Pivot, Bottom Retainer, Spring Spring, Compression Bumper Bolt Washer, Flat Hubstrut, LH Hubstrut, RH

Ref. Part No.

Qty. Description

13 14 15 16 17

7710507 3514342 7080306 7542324 -------

2 2 2 4 1

18 19 20 21 22

7552901 7512365 7080367 5211115 7041762

4 4 2 2 2

Ring, Retaining Bearing, Hubstrut Fitting, Lubrication Nut, Nylok Asm., Front Brake Caliper, LH (See Front Brake Pg. B5 for Details) Washer, Spring Lock Screw Clamp, Rubber Coated Washer Strut, Front

9/04

B13

FRONT WHEEL SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

8

9

7 E 2004 Polaris Sales Inc.

6 4 2

5

3 10

1

12

11

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 5412396 2 1520269-067 1520269-486 3 5411164 4 7661401 5 7556004 6 5134310

Qty. Description

2 2 2 2 2 2 2

Tire, Front, 25x8-12 Rim, Front, Black (AB)(AH) Rim, Front, Silver (AG) Cover, Dust Pin, Cotter Washer Hub

Ref. Part No.

7 8 9 10 11 12

7515513 5244314 7512325 7542810 1525017 7547237

Qty. Description

8 2 8 2 2 8

Stud Disc, Brake Bolt Nut, Slotted Valve, Rim Nut 7/04

B14

HANDLEBAR and HEADLIGHT POD SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 1

E 2004 Polaris Sales Inc. 2

30

6 31 32

3

29

28

35

4 6

5

33 8

7

9 27

34

26 10

13

25 22

11

24 23

12 14 15 16

21 20

17

15

19 18

C1

HANDLEBAR and HEADLIGHT POD SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

1 4011074 2 5435364-400 5435364-293 5435364-341 3 5434380 4 3280431 5 5412138 6 7511881 7 -------

1 1 1 1 1 1 1 3 1

8 9 10 11 12 13 14 15

1 1 1 1 2 1 1 1 1 1

5843350 4122550 7080138 7670127 5410163 7080922 5433534 4011002 4010278 4010321

Switch, Worklight Pod, Headlight, Upper (AH) Pod, Headlight, Upper (AB) Pod, Headlight, Upper (AG) Bezel Cluster Mount, Rubber Screw Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B9, Ref. 5) Knob, Adjusting Rod, Adjusting Cable Tie Clip, Screw O-Ring Nut, Choke Cover, Key Switch, Key, 3 Position (Incl. Key) Blank, Key, Series 2000, 6700, 6800 Blank, Key, Series 2200, 2300, 2700, 2800 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key.

Ref. Part No.

Qty. Description

16 17 18 19 20 21 22 23 24 25 26 27

5435365-177 7517658 5132382 4010298 7542122 7081176 4010638 7517317 5244969-067 5631516 5631517 -------

1 1 1 1 4 1 1 2 1

28 29 30 31 32 33 34 35

5432952 7517625 5433834-070 4010592 5433903 5242987-067 7515189 2410429 4831060

1 1 2 1 1 1 4 1 1

1 1

Pod, Headlight, Lower Screw Cap Sensor Nut, Nylok Cable, Choke Receptacle, Pod Mount, 12V Screw Bracket, Pod Mounting Block, Handlebar Block, Handlebar, Pegged Asm., Master Cylinder (See Controls Pg. B4 for Details) Plug Screw, Set Grip, Handlebar Switch, Handlebar, Hi/Lo/Off Spacer, Switch, LH Tube, Handlebar Screw Asm., Headlight Bulb, Headlight 7/04

C2

TAILLAMPS/WORKLAMPS/HEADLIGHTS SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc. 1 8

10

7 9

2

6

5

4 3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2410427 2410428 2 7670054 3 7517561 4 7670112 5 2410425 2410426

Qty. Description

1 1 4 2 2 1 1

Asm., Tail/Worklight, LH Asm., Tail/Worklight, RH Nut, Speed Screw U-Nut Asm., Headlight, LH Asm., Headlight, RH

Ref. Part No.

6 7 8 9 10

4011066 4011102 4011065 4011101 4011064

Qty. Description

2 2 2 2 2

Bulb, Bumperlight Socket, Worklight Bulb, Worklight Socket, Taillight Bulb, Tail/Stop 7/04

C3

A-ARM/STRUT MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

24

1 2

E 2004 Polaris Sales Inc. 25

26

28

3 4

26 28

5

25

24

23

27 22

6 7

21 8 9

10

18

11

19

20

17 12 8

14

13

15

16

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 ------2 3 4 5 6 7 8 9 10 11 12 13

7080927 5211121 5410548 7512284 2202906 2202907 7542438 7661203 5435028-070 5435029-070 7512084 7517909 7556099 7547177

Qty. Description

1 Asm., Hubstrut (See Front Strut Pg. B13, Ref. 12) 2 Joint, Ball 2 Bracket, Ball Joint 2 Boot, Rubber 4 Screw 1 Kit, A-Frame, LH (Incl. 8,24,25,27,28) 1 Kit, A-Frame, RH (Incl. 8,24,25,27,28) 2 Nut, Castle 4 Pin, Cotter 1 Shield, CV Joint, LH 1 Shield, CV Joint, RH 6 Screw 2 Bolt 4 Washer, Flat 2 Nut

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

5411920 7061054 7547028 5134242 7542711 7061034 5411291 1821498 7515415 7542439 7512492 7552603 7555832 5133806 5434551

Qty. Description

1 2 2 2 2 2 2 2 2 2 4 4 4 2 4

Boot, Seal, Rod End Rod End, LH Nut, Jam, LH Tie Rod Nut Rod End Boot, Seal, Rod End Asm., Tie Rod (Incl. 14-20) Screw Nut, FLEXLOC Screw Washer, Spring Lock Washer Shaft, A-Arm Bushing, A-Arm, Long 7/04

C4

STEERING POST SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 2

E 2004 Polaris Sales Inc.

1

3 10 3 4

5 6

7

1

5 10

8

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5

7517428 5246732 5433866 1822630-067 7556162

Qty.

4 1 2 1 2

Description

Ref. Part No.

Bolt, Carriage Bracket, Steering Post, Upper Bushing, Steering, Upper Post, Steering Bushing

6 7 8 9 10

5222393 3514352 7547158 7661633 7542343

Qty.

1 1 1 1 4

Description

Flangette Bearing Nut Pin, Cotter Nut, Nylok, Flange 7/04

C5

GEAR SELECTOR SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1 2 E 2004 Polaris Sales Inc.

3 4

9

11 10

5 4

6

8

5

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6

5412003 7512024 5411007 7515175 7542122 1822730

Qty. Description

1 1 1 2 2 1

Cover Screw Knob, Gear Selector Screw Nut, Nylok Asm., Linkage

Ref. Part No.

7 8 9 10 11

1013315-067 7542324 8360012-10 5435042 7518342

Qty. Description

1 2 1 2 2

Selector, Gear Nut, Nylok Trim, Edge Mount, Gear Selector Screw 7/04

C6

DRIVE CLUTCH SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc. 4 1

2

3

5

8

6

9

7

12

11 10

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1321976 1 2 3 4 5 6

7518062 3576510 7042202 5430945 1321457 5431936

Qty. Description

1 Asm., Drive Clutch, Basic (Incl. All Less 3,8) 6 Bolt 1 Bearing, Cover 1 Spring, Clutch 6 Washer, Multilube 3 Asm., Roller and Bushing 6 Button, Guide, Stemless

Ref. Part No.

Qty. Description

7 5210752 5242981 5210753 5210754 8 5630710 9 7512266 10 7541906 11 3576504 12 5020422

AR AR AR AR 3 3 3 1 3

Spacer, .020 Spacer, .025 Spacer, .032 Spacer, .050 Weight, Shift, 10 WH Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable, 1/2 Inch Pin, Roller 7/04

C7

DRIVEN CLUTCH SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1 E 2004 Polaris Sales Inc. 2 16 15

17

4 14

3

5 6

13 12 11

10 9 3

8

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

1 2 3 4 5 6 7 8 9

AR 1 1 1 1 1 AR AR AR

10 11 12 13 14 15 16 17

7556120 3211077 1321848 5220646 7552901 7515327 7555898 7556076 7556804

Bushing (3 Max) Belt, Drive Asm., Driven Clutch (Incl. 7-17) Washer, Domed Washer, Spring Lock Bolt Washer (.020) Washer (.025) Washer (.030)

3576504 3576511 7041782 5131446 5210752 7710448 7511854 5430766

Qty. Description

1 1 1 1 1 1 3 3

Bearing, Moveable, 1/2 Inch Bearing, Moveable, 1 Inch Spring, Clutch Ramp, Stationary Spacer Ring, Retaining Bolt Button, Ramp 7/04

C8

CLUTCH COVER SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

9 7

10

8

11

6 10

4 5

12 3

1

13

2

14

15

E 2004 Polaris Sales Inc.

16 17

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

2201954 7517599 7080511 5435236 5521578 5434255-070 5410542 5434264 5411489

Qty. Description

1 5 1 1 1 1 1 1 1

Kit, Inner Clutch Cover (Incl. 14) Asm., Bolt/Washer Clamp, Narrow Band Duct, Clutch Air Inlet Seal, Cover, Clutch Cover, Clutch, Outer O-Ring Plug, Drain Boot, Duct

Ref. Part No.

10 11 12 13 14 15

7080707 5435235 7172746 7172563 7512094 -------

16 5242046 17 5410575

Qty. Description

2 1 1 1 9 3

Clamp, Narrow Band Duct, Clutch Outlet Decal, “Automatic Transmission” Decal, Warning, Clutch Cover Screw Screw and Washer (See Crankcase Pg. D4, Ref. 6) 1 Bracket, Clutch, Seal 1 Seal, Cover Case 7/04

C9

REAR WHEEL DRIVE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

12 11 10 E 2004 Polaris Sales Inc.

9 8 13 6

7 5

4 3

2

1

15

14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 5412451 2 1520457-067 1520457-486 3 5411164 4 7543005 5 5244635 6 7661404 7 7555796 8 5134311

Qty. Description

2 2 2 2 2 2 2 4 2

Tire, 25x11-12 Rim, Rear, Black (AB)(AH) Rim, Rear, Silver (AG) Cover, Dust, Hub Nut, Castle Disc, Brake, Rear Pin, Cotter Washer, Cone Hub, Rear Wheel

Ref. Part No.

9 10 11 12

7515513 7710440 3585502 -------

13 7512325 14 1525017 15 7547237

Qty. Description

8 2 2 2

Stud Ring, Retaining Bearing Carrier, Bearing, Wheel (See Rear Suspension Pg. C12, Ref. 11) 8 Screw 2 Valve, Rim 8 Nut, Flange 7/04

C10

REAR SUSPENSION SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

4

3

2

7

1

4

5

18

3

35 37

6 8

18 36

2

9

30

29

8

26 28

28

8

18 22

29 21

31

30

8 7

20

E 2004 Polaris Sales Inc. 11 12

13 14

19 15

16 18 17

C11

24

25

27

32

9

18

26 34

33

10

36

35

23

REAR SUSPENSION SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

6 6 2 2 1 2 4 8 8 2 2 4 8 4 4 4 2 10 2 2

21 22 23 24 25 26 27

7518341 7542343 7555939 5434549 5334114-067 1580107-067 7517231 7555761 5432598 5020827 5134206 5631142 5434550 7552614 7555740 7517873 7515415 7542439 7043100 5630551

Bolt, Flange Nut, Nylok Washer Bushing, Stabilizer Tube Bar, Stabilizer Tube Arm, Stabilizer Bar Screw Washer, Flat Bushing, Stabilizer Rod, Linkage, Stabilizer Carrier, Wheel Bearing Bushing, Bearing Carrier Bushing, Control, Lower Washer, Lock Washer, Flat Bolt Screw Nut, Nylok Shock, Rear Cam, Adjusting, Spring

28 29 30 31 32 33 34 35 36 37

7043091-067 5630885 7515433 5247345 7518364 5020826 1014320-293 1014321-293 5434551 7552603 7512492 1014174-293 1014175-293 7512084 5435008-067 5435009-067 5133806 7515472 5434548 1541802-067

Qty. Description

2 2 2 2 4 6 1 1 4 4 4 1 1 4 1 1 2 6 12 1

Spring, Compression, Rear Retainer, Spring Screw Bracket, A-Arm Pivot Screw Shaft, A-Arm, Short Arm, Control, Upper, LH Arm, Control, Upper, RH Bushing, A-Arm, Long Washer, Spring Lock Screw Arm, Control, Lower, LH Arm, Control, Lower, RH Screw Shield, Rear, LH Shield, Rear, RH Shaft, A-Arm Screw Bushing, A-Arm, Short Support, Stabilizer 7/04

C12

ELECTRICAL/TAILLIGHT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

19

1

18

17

16

20

2

19 3

21

22

14

24

4 5

15

23 27

26

25

13

6

11

7 12

E 2004 Polaris Sales Inc.

8

10

11

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

5431769 2202848 4011138 4011139 5810290 7512232 2410535 2410466 2202147 4010924 4011110 7512024 5246747 5810317

Qty. Description

1 1 1 1 3 1 1 1 1 1 1 4 1 1

Cover, Battery Kit, Battery Bolt Battery Cable, Battery/Frame Pad, Battery Screw Harness, Winch Harness, Main Kit, Fusible Link Module, Resistor Module, Controller Screw Bracket, CDI Pad

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26 27

7541925 7512007 7080138 4020139 7080965 7010032 5412499 7552801 7547283 7512027 4010094 4010093 7518287 4011072

Qty. Description

1 1 12 3 3 2 1 2 2 2 1 1 2 1

Nut, Nylok Screw Cable Tie Clip, Rosebud Mount, Cable Tie Hook, Battery Strap Strap, Battery Holddown Washer, Spring Lock Nut Screw Cable, Battery/Solenoid Cable, Solenoid/Starter Nut Switch, Magnetic 7/04

C13

TRANSMISSION MOUNTING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc. 7

9

2

8

7 6

5 4

3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

1 2 3 4 5

3 3 4 1 AR

7518365 7547180 7518364 7080307 8450003

Screw Nut, Flange Screw, Flange Clamp Line, Fuel

Ref. Part No.

6 7 8 9

7515382 7542343 7515398 5221624-067

Qty. Description

1 3 2 1

Screw Nut, Flange Screw, Flange Support, Transmission, Upper 7/04

C14

GEARCASE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

24

7

25

23 E 2004 Polaris Sales Inc.

18

21

22

20

19

27

18

26

17 15 12 13

16

14 31

11 32

8

65 64

67 68

63

62

61

2

24

60

45

41 44

50

59 58

69 72 74

71

80

56

70

73

75

57

73

74

75

71

76

70

77 78

79

D1

55

54

53

51

52

38 47 48

46

16

27

40

43

14

46

37 39

41 42

35

33

6

66

34

34

9 3 5 1 2 4

35

35

10

7

36

29 28 30

49

GEARCASE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1341450 3233906 3233826 3233827 3233829 3233869 3233831 3233878 3233832 3233524 3234059 3234066 3234065 3234064 3233364 3234063 3234086 3234062 3233268 3234058 3234057 3233247 3234056 3233846 3234087 3233874 3233749 3233018 3234061 3234060 3233699 3234080 3234088 3233915 3233851 3233718 3233176 3234067 3234068 3233855 3234070

Qty. Description

Ref. Part No.

1 1 8 1 1 1 1 2 1 1 1 1 1 1 2 1 5 1 2 1 1 2 1 22 2 1 2 2 1 1 1 1 1 1 2 3 1 1 1 1 1

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Asm., Gearcase Bellcrank Screw Cover, Gear Pawl, Detent O-Ring Shaft, Shift Seal, Triple Lip Gear, 31T Tube, Vent Gearcase, RH Shaft, Center Drive Bearing, Ball Spacer Ring, Retaining Cover, Bearing Screw Gear, Output, 91T Bearing, Ball Sprocket, 59T Chain Pin, Dowel Gearcase, LH Screw Plug Seal, Dual Lip Screw Bearing Deflector, Oil Sprocket, 19T Ring, Retaining Drum, Shift Baffle, Oil Plate, Park Washer Bearing, Needle Washer, Thrust Ring, Retaining Gear, 28T Washer Dog, Engagement

3233850 3233854 3234071 3233852 3234069 3234074 3233019 3234075 3233036 3233357 3234092 3234076 3233788 3233106 3233305 3234085 3234084 3233265 3234083 3233917 3233839 3233548 3234081 3234082 3233076 3233830 3233961 3233834 3233835 3234091 3234077 3234073 3234089 3234078 3234090 3233432 3233433 3233434 3233431 3234079

Qty. Description

2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 2 2 2 1 1 1 1

Ring, Retaining Sprocket, 24T Shaft, Reverse, 26T Gear, 33T Dog, Engagement Bearing, Ball Bearing Asm., Input Shaft Chain, Silent Spacer Ring, Retaining O-Ring Seal, Triple Lip Ring, Snap Bearing, Ball Tube, Snorkel O-Ring Bearing, Ball Shaft, Snorkel Asm., Park Lockout Gear, 16T O-Ring Disc, Lockout Star, Detent O-Ring Spring, Compression Nut, Lock Ring, Retaining Switch Washer Fork, Shift Collar, Shift Spring, Compression Spring, Compression Ring, Retaining Pin, Dowel Shoe, Chain Tensioner Cam, Chain Tensioner Spring, Torsion Rail, Shift Shaft 5/03

D2

FRONT HOUSING SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

1 2

3 4 16

14 5

7

6 15

2

28

13 8

15

12

9

27

11

5

16

10 26

25

20

19

18

17

21

4 24

22 23

15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

1341497 3233955 1 3234163 2 3234159

1 1 1 1

3 4 5 6 7 8

3234161 3233926 3233953 3233928 3234166 3234167

1 2 1 1 1 1

9 10 11 12 13

------3233957 3234169 7080307 8450003 7512024

1 14 1 1 AR 1

Asm., Front Gearcase Kit, Bolt Screw, Set Asm., Cover Plate (Incl. Output Cover, Insert and Coil) Shim, Armature Plate Bearing, Roller Ball Asm., Race/Output Hub (Incl. 25) Pin, Dowel Clutch Housing/Ring Gear Asm., Roll Cage (Incl. Spring and Roll Cage) Spring Kit, Roll Bushing Clamp Line Screw

Ref. Part No.

14 7080693 15 3233956 16 17 18 19 20 21 22 23 24

3233918 3233947 3234112 3233944 ------------3233942 7518364 3233951

25 26 27 28

3233929 3234168 3234162 3234160

Qty. Description

1 Clamp 1 Kit, Minor Repair (Incl. O-Rings and Seals) 11 Bolt 1 Cover, Input 1 Bearing, Roller Ball 1 Shaft, Pinion, 11T 1 Bushing 1 Gearcase, LH 1 Plug, Oil Fill 4 Screw, Flange 1 Asm., Drain Plug (Incl. Plug and Washer) 1 Bearing, Needle, Roller Thrust 1 Asm., Clutch (Incl. 7-9) 1 Ring, Retaining, Internal 1 Plate Armature 7/04

D3

CRANKCASE SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

6

2 E 2004 Polaris Sales Inc.

7 5

3

8

2

1

4 9 10

23

22 15 21

16

20

18

5 14

13

12

11

17

19 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 3083669 2 3089240 3 4 5 6 7 8 9 10 11

3087266 3080676 3084840 3084205 3084839 3085525 3087154 3084842 3084845

Qty. Description

1 Bushing, Starter 1 Asm., Crankcase (Incl. 1,4,5,7,8,15,16,17,20,21,23) 2 Pipe, Knock 1 Bearing, Ball 2 Pin, Dowel 3 Screw and Washer 1 Seal, Oil 1 Pipe, Air Breather 1 Fitting, Oil Inlet 1 Union 1 Plug

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22 23

3084846 3084844 3086810 3084834 3084835 3084841 3082956 3086749 3084837 3084836 3084847 3086838

Qty. Description

1 1 1 2 1 10 1 1 1 1 1 2

Gasket, Aluminum Spring, One Way Valve Valve, One Way Bearing, Ball Bearing, Ball Bolt, Flange Gasket Plug Seal, Mechanical Seal, Oil O-Ring Pin, Dowel 7/04

D4

CYLINDER SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 2

1

8

7

3 4

5

6

9 11

10

37 36

35

12 16

5 13

17 18

31

34

33

15 14

19

32 24

8

23

21

22

20

25

30

26 27 28 29

16

E 2004 Polaris Sales Inc.

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty. Description

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 1 2 2 4 2 1 10 1 1 1 1 1 1 2 10 4 1 1

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

3083166 3081497 3081330 3084857 3084994 3084858 3084870 3084877 3084866 3084867 3085073 3085074 3084861 3084860 3084859 3084874 3084875 3085854 3084864

Asm., Band, Adapter (Incl. 2) Screw Bolt, Socket Head Pin, Straight Guide, Valve Seal, Intake Valve Adapter, Water Out Bolt, Flange Adapter, Camshaft O-Ring Cover, Rocker Gasket, Rocker Cover Gasket Plug Seal, Exhaust Valve Bolt, Flange Bolt, Cylinder Head Bolt, Rocker Shaft Support, Valve Rocker Shaft

3084876 3084863 3080530 3087199 3085326 3087266 3084849 3084873 3089241 3086747 3085370 3084862 3089242 3085075 3086781 3085337 3085527 3084879

Qty. Description

4 1 2 2 2 2 1 4 1 1 1 1 1 1 2 1 1 1

Bolt Support, Valve Rocker Shaft Washer, Lock Nut Stud Pipe, Knock Union, Oil Pump Bolt, Flange Cylinder (Incl. 29) Pipe, Elbow, 2 Gasket, Cylinder Plug, Blind Cover, Camshaft Gasket, Exhaust Bolt, Flange Gasket, Head Head, Cylinder (Incl. 4-6,13-15,24,31) Adapter 7/04

D5

CRANKSHAFT and PISTON SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 4 1

3

2 1 5

6

7

21 8 9

20

10

E 2004 Polaris Sales Inc.

11

12

15 19

16 18

13

17

14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 3085534 2 ------3 3087230 3087231 3087232 4 3087233 3087234 3087235 5 3085815 6 3088719 7 3087090 8 3086206 9 3085343 10 3085024 11 3089573 3089574

Qty. Description

2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1

Clip Pin, Piston Piston Set (Std)(Incl. 1) Piston Set (0.25 mm O/S)(Incl. 1) Piston Set (0.50 mm O/S)(Incl. 1) Ring Set, Piston (Std) Ring Set, Piston (0.25 mm O/S) Ring Set, Piston (0.50 mm O/S) Bearing, Ball Crankshaft 2 Pin, Crank Rod, Connecting Bearing, Large End Ball, Steel Asm., Crankshaft (Incl. 6-12) Crankshaft 1

Ref. Part No.

12 3089245 13 3085404 14 3084895 3084896 3084897 15 3240088 3084892 3084893 3084894 16 3084882 17 3085528 18 3086767 19 3083905 20 3081447 21 3081543

Qty. Description

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Balancer, Gear 1 Shaft, Balancer Spacer (0.8) Spacer (1.0) Spacer (1.2) Spacer (0.6) Spacer (0.8) Spacer (1.0) Spacer (1.2) Sprocket 1 Nut, Slit Washer Nut, Lock Key Key, Woodruff 8/04

D6

CARBURETOR SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1 2

45

5

E 2004 Polaris Sales Inc.

44

6

43 3 4

42

7 13 10

41

8

12

11

14

9

16 15

40 39

17 18 37

38

21

19 22

25

36

23

26

35

24

27

34 33

28

32

29 30 31

D7

21

20

CARBURETOR SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

3130507 3130508 3130541 3130540 3130924 3130503 3130505 3085698 3131589 3130625 3131228 3130538 3131396 3130511 3130535 3130543 3130513 3130501 3130514 3130589 3130515 3130502 3130836

Qty. Description

1 1 2 2 4 1 1 2 1 1 1 1 1 1 4 1 1 2 1 1 2 1 1

Ring E-Ring Screw Washer, Spring Screw Cover Spring Screw and Washer Asm., Carburetor (Incl. All less 8,14-16) Jet, Air, #160 Asm., Plunger Spring Holder, Guide Cover Screw Guide, Cable Shaft, Throttle Screw Ring Spring Seal Valve, Throttle, 100 Spring

Ref. Part No.

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

3131423 3130624 3131360 3130533 3130529 3130521 3130590 3130520 3130532 3130591 3130594 3130361 3130519 3130518 ------3131570 3130014 3130504 3131311 3130732 3130752 3131312

Qty. Description

1 1 1 1 1 1 1 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1

Screw, Adjust Jet, Pilot, #40 Valve, Needle (1.5) O-Ring Float Screw Body, Float Screw O-Ring Screw Plate Pin, Float Cap E-Ring Packing Jet, Main (#172.5) Washer Block, Jet Jet, Needle (Q-0) Diaphragm Ring Needle, Jet (5F14) 8/04

D8

INTAKE and EXHAUST SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH E 2004 Polaris Sales Inc.

6

7

9 8

7 6

1 2

11 12

10

3 4 5

28

14

13 8

6

15

7

16 17

27 18

26

13

12

11

19 25 24 23 21

22

20

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

3087129 3087130 3087131 3087132 3086493 3084912 3084911 3084910 3084909 3084913 3084908 3087203 3086892 3086212

Qty. Description

1 1 1 1 1 4 4 2 1 1 8 4 4 1

Plug Gasket Spring Pin Asm., Tensioner (Incl. 1-4) Nut Screw, Adjusting Asm., Rocker Arm, Intake (Incl. 6,7) Shaft, Rocker Asm., Rocker Arm, Exhaust (Incl. 6,7) Valve, Collet Retainer, Spring Spring, Valve Camshaft (Incl. 15-18)

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27 28

D9

3086838 3085348 3085076 3084899 3084914 3084916 3081657 3084915 3084924 3084917 3085349 3085412 3086448 3083361

Qty. Description

1 1 1 1 1 1 3 1 1 1 2 2 1 2

Pin, Dowel Lever, Release Spring, Return Pin, Dowel Sprocket 2 Guide, Chain Bolt and Washer Chain, Timing Bolt, Pivot Lever Lever Valve, Intake Valve, Exhaust Gasket, Tensioner Asm., Bolt and Washer

7/04

WATER PUMP SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 3

E 2004 Polaris Sales Inc. 4

1

2 1

6 9

8

5

7

10 11

7

12 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6

3086774 3085857 3084940 3089246 3084942 3084935

Qty. Description

2 1 1 1 1 1

Clamp, Hose Hose, Main Thermostat Asm., Thermo Sensor Washer, Seal Impeller

Ref. Part No.

7 8 9 10 11 12

7555998 3085077 3086840 3085351 3085359 3084877

Qty. Description

2 1 1 1 1 4

Washer, Flat Nut, Self Lock Gasket, Water Pump Cover, Water Pump Bolt, Flange Bolt, Flange 7/04

D10

FUEL PUMP SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

2

3

2

4

1

4

E 2004 Polaris Sales Inc.

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

3085275 1 3084999 2 3085356

Qty. Description

1 Asm., Fuel Pump (Incl. 1-4) 1 Screw and Washer 2 Screw and Washer

Ref. Part No.

3 3084591 4 3088170

Qty. Description

4 Screw & Washer 1 Diaphragm, Gasket Set 7/04

D11

OIL PUMP SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

4

3 2 1 6 9 8

5

10 11

7

14

12

15 13

17

16 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

3084946 3084949 3084948 3087276 3087264 3084955 3085535 3084954 3084962 3087265

Qty. Description

1 1 1 1 1 2 1 2 3 1

Pump, Oil, Case 2 Rotor, Outer, Feed Rotor, Inner, Feed Asm., Oil Pump (Incl. 1-7,9-15) Pump, Oil, Case 1 Pin, Dowel Screw Pin, Dowel Bolt and Washer Pump, Oil, Case 3

Ref. Part No.

Qty. Description

10 11 12 13 14 15 16 17

1 1 1 3 1 1 1 AR AR AR

3084950 3084951 3084956 3084205 3084953 3084952 3084958 3084959 3084960 3084961

Rotor, Inner, Scav Rotor, Outer Unit, Oil Strainer Screw and Washer Washer Shaft, Pump Gear, Pump, 2 Spacer (0.8) Spacer (1.0) Spacer (1.2) 7/04

D12

OIL FILTER SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

2 3

2 5

3 2

2

3 4

E 2004 Polaris Sales Inc.

2

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 3084963 2 3084846 3 3086815

Qty. Description

1 Oil Filter 8 Gasket, Aluminum 4 Bolt, Banjo

Ref. Part No.

4 3084965 5 3084964

Qty. Description

1 Pipe, Oil Delivery 2 1 Pipe, Oil Delivery 1 7/04

D13

RECOIL STARTER SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 3

2

1

5

4

6

7 8 9 14

11

13

10

E 2004 Polaris Sales Inc.

8

12

7 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8

3084822 3083463 3083378 3083379 3084744 3085266 3086749 3082956

Qty. Description

1 1 1 1 1 1 2 2

Reel Spring, Return Ratchet Spring, Friction Plate, Friction Bolt and Washer Plug Gasket

Ref. Part No.

9 10 11 12 13

3083669 3083185 3084750 3084877 3087163 3087164 14 3085083

Qty. Description

1 1 1 9 1 1 1

Bushing, Starter Spring, Spiral Bushing Bolt, Flange Asm., Recoil (Incl. 1-6,9-11,13,14) Starter Case (Incl. 11) Asm., Rope 7/04

D14

STARTING MOTOR SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH 3

4

2

E 2004 Polaris Sales Inc.

5

1 6 1 7

8

12

10

13

11

9

14 15

16 17 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8

3084981 3084982 3088169 3083649 3084408 3085034 3082038 3085353 3085033

Qty. Description

1 1 1 2 3 1 2 1 1

Starting Motor (Incl. 1-5,7-10,12) Washer Set Brush, Carbon Nut, Flange O-Ring Bracket, Rear Bolt and Washer Armature Asm., Front Bracket (Incl. 9)

Ref. Part No.

9 10 11 12 13 14 15 16 17

3240114 3084983 3087030 3084405 7555908 3084412 3084411 3084410 3084409

Qty. Description

1 2 1 2 1 1 1 1 1

O-Ring Asm., Bolt Set (Incl. 4) Asm., Gear Shaft (Incl. 14-17) Ring, Rubber Washer, Thrust Clip Spring, Weight Spring, Return Clip 7/04

E1

MAGNETO SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

2

1 3

16

15

13

4 14

12 5 10

11

6 8

7

9 E 2004 Polaris Sales Inc.

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

Qty.

1 2 3 4 5 6

1 1 1 1 1 1 1 5 1

3089239 3084980 3070175 3084978 3084972 3089545 3089248 7 3081657 8 3084973

Description

Coil, Ignition Cap, Spark Plug Plug, Spark O-Ring Metal, Bearing Asm., Plate (Incl. 5,8-15) Plate Bolt and Washer Seal, Oil

Ref. Part No.

Qty.

9 10 11 12 13 14 15 16

1 1 3 2 1 1 1 1

3089546 3089544 3089547 3084976 3089250 3089254 3081256 3089238

Description

Stator (Incl. 13) Flywheel w/Ring Gear Screw and Washer Screw and Washer Band, Pulse Coil, Pulser Screw and Washer CDI System 8/04

E2

TOOL KIT SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

8

2

3

9 4

5

6

E 2004 Polaris Sales Inc.

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

3085383 2874924 1 2 3 4

2870725 3082657 3085001 3085002

Qty. Description

Ref. Part No.

1 Kit, Tool (Incl. 2-8)(If built before 8/02/04) 1 Kit, Tool (Incl. 2-8)(If built after 8/02/04) 1 Gauge, Tire Pressure 1 Screwdriver 1 Wrench, 8-10 Open 1 Wrench, 12-14 Open

5 6 7 8

3085568 3085569 2682572 2873647 2874858 9 9919412

Qty. Description

1 1 1 1 1 1

Wrench, Box Puller, Spark Plug (Wrench Handle) Pouch, Tool Kit Wrench, Torx (If built before 8/02/04) Wrench, Torx (If built after 8/02/04) Owner’s Manual, ‘05 Sportsman 4/5/6/700 7/04

E3

PRINTED IN THE USA

PARTS MANUAL PN 9919413 and MICROFICHE PN 9919414 7/04