POLARIS SPORTSMAN 4. SERVICE MANUAL Pdf Download.- projex@inbox. CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM/CARBURETION CHAPTER 5 BODY / SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 1. ELECTRICAL..... 1. Specifications - Sportsman 4. GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 1 C H 5 0 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation..- projex@inbox.

GENERAL INFORMATION REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series # Part Number 4. GENERAL INFORMATION MODEL COLOR IDENTIFICATION SPORTSMAN 4. A0. 1CH4. 2AA SPORTSMAN 4.

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A0. 1CH4. 2AB..- projex@inbox. GENERAL INFORMATION MODEL COLOR IDENTIFICATION SPORTSMAN 4. A0. 1CH4. 2AC..- projex@inbox. GENERAL INFORMATION MODEL COLOR IDENTIFICATION SPORTSMAN 5.

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H. O. DUSE - A0. 1CH5. AF SPORTSMAN 5. 00 H. O. RSE - A0. 1CH5. AJ..- projex@inbox. GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 4. SPORTSMAN 5. 00 2.

GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 4. SPORTSMAN 5. 00 8. GENERAL INFORMATION MACHINE DIMENSIONS 4.

SPORTSMAN 4. 00 1. SPORTSMAN 5. 00 4. GENERAL INFORMATION SPORTSMAN 4. MODEL: . MODEL NUMBER: A0.

CH4. 2AA/AB/AC ENGINE MODEL: EH4. PLE0. 5 JETTING CHART AMBIENT TEMPERATURE Altitude Altitude Below 4.

MODEL: . MODEL NUMBER: A0. CH5. 0AA/AB/AE/AF/AJ ENGINE MODEL: EH5.

PLE1. 3 JETTING CHART AMBIENT TEMPERATURE Altitude Altitude Below 4. Owner’s Manual Parts Parts Manual PN Micro Fiche PN 2. Sportsman 4. 00 A0.

CH4. 2AA/AB/AC 9. Sportsman 5. 00 DUSE A0. CH5. 0AD 9. 91. 57. Sportsman 5. 00 H. O. A0. 1CH5. 0AA/AB/AE/..- projex@inbox. GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline.

There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.- projex@inbox. GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch 1. GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch 1.

GENERAL INFORMATION DECIMAL EQUIVALENTS 1/6. GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. Polaris measures chain length in number of pitches. CI: Cubic inches. Piston Clearance: Total distance between piston and cylinder wall.

PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator.

Regulates battery charging system output at approx. DCV as engine RPM increases.- projex@inbox. CHAPTER 2 MAINTENANCE Periodic Maintenance Chart .. Pre- Ride Inspection ... Recommended Lubricants and Capacities .

Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re- placement parts. Always use genuine Polaris parts.

HCAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.- projex@inbox. MAINTENANCE PERIODIC MAINTENANCE CHART, CONT. CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles Remarks (Km) . Do not force fluid into hub. Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir.

COLD WEATHER KITS FOR 4 CYCLE ATVS Oil Tank Cover - - PN 2. Engine Heater - - PN 2.

MAINTENANCE POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD- UCT PART NUMBERS Part No. Description Engine Lubricant 2. Fogging Oil 2. 87. Engine Oil (Quart) Premium 4 Synthetic 0- W4. Cycle) 2. 87. 15. Engine Oil (1. 6 Gallon) Premium 4 Synthetic 0- W4. Cycle)Add lube to FULL level on dip- Change annually .

Lubricant Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to in- As required. Change fluid every 2 years. Brake Fluid dicated level inside reservoir. See page 2. 3. 6. Annually or 1. 00 hours of operation (refer to Maintenance Schedule for additional information) . Polaris Premium All Season Grease, Conoco Superlube M or . Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special..

Annually or 1. 00 hours of operation (refer to Maintenance Schedule for additional information) . Polaris Premium All Season Grease, Conoco Superlube M or . S Check vent hose to be sure it is routed properly and unobstructed. S The correct gearcase lubricant to use is Polaris Premium GL5 8. Gear Lube, or an equivalent lubricant with a GL5 rating. S Check vent hose to be sure it is routed properly and unobstructed.

TRANSMISSION SPECIFICATIONS Dipstick Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2. Gallon) PN 2. 87. Capacity: . At change: Approx.

MAINTENANCE TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT, PRE- LIMINARY INSPECTION S If shifting problems are encountered, the transmis- Linkage rod will rotate sion linkage can be adjusted. S Tighten shift linkage rod end jam nuts properly after adjustment.- projex@inbox. MAINTENANCE SHIFT LINKAGE ADJUSTMENT, CONT. Place gear selector in neutral.

Make sure the transmission bell cranks are engaged in the neutral position detents. Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Adjust the low range (inside) rod so the rod end is centered on the transmission bell crank.- projex@inbox. MAINTENANCE THROTTLE OPERATION Check for smooth throttle opening and closing in all han- dlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Place the gear selector in neutral. Set parking brake.

MAINTENANCE PILOT SCREW ADJUSTMENT Pilot Screw (Idle Mixture) Adjustment Notes Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged. Start engine and warm it up to operating temperature (about 1. This is a very important step. MAINTENANCE THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT 1. Where To Buy Crack Pipes here. Slide boot off throttle cable adjuster and jam nut. Place shift selector in neutral and set parking brake. Start engine and set idle to specified RPM, then shut off engine.- projex@inbox.

MAINTENANCE FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.- projex@inbox. MAINTENANCE CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before ex- tended periods of storage. NOTE: The bowl drain screw is located on the bottom left side of the float bowl.- projex@inbox. MAINTENANCE COMPRESSION TEST NOTE: 4- Stroke engines are equipped with an automatic decompressor.

Compression readings will vary in pro- portion to cranking speed during the test. Average compression (measured) is about 5. Smooth idle generally indicates good compression.- projex@inbox. MAINTENANCE BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. It contains sulfuric acid.

Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.- projex@inbox. The Last Airbender 2010 Encoded Text. MAINTENANCE SPARK PLUG 1. Remove spark plug high tension lead. Clean plug area Recommended Spark Plug: so no dirt and debris can fall into engine when plug is removed.

Refer to Specifications 2. Remove spark plug. Inspect electrodes for wear and carbon buildup.