2012 – 2014 Polaris Sportsman 400 500 ATV Service Manual

Description

This Official 2012 – 2014 Polaris Sportsman 400 And Sportsman 500 ATV  Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for:

2012 Polaris Sportsman 400 HO ATVs
2013 Polaris Sportsman 400 HO ATVs
2014 Polaris Sportsman 400 HO ATVs
2013 Sportsman 400 HO South Edition ATVs
2014 Sportsman 400 HO South Edition ATVs
2012 Sportsman Forest 500 International ATVs
2012 Sportsman Forest Tractor 500 EFI /HO / International ATVs
2013 Sportsman Forest Tractor 500 EFI / HO /  International ATVs
2014 Sportsman Forest Tractor 500 EFI ATVs

Service Manual Table of Contents

General Information
Maintenance
Engine
Fuel System – General
Body / Steering / Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical

Service Manual Index of Topics

A
A-Arm Replacement
Accessory Power Wiring
Active Descent Control Gearcase
ADC Gearcase Piston Service
ADC Gearcase, Disassembly / Inspection
Adjustments, Seat
Air Control Body, Speed Control
Air Filter, Service
Alignment, Wheel
All Wheel Drive (AWD) Coil
All Wheel Drive and Speedometer Troubleshooting Tests
Alternator / Ignition Components
Alternator Output Test
Authorization Key
Authorization, Reflash
Axle, Front Drive
Axle, Rear Drive
B
Ball Joint Replacement, Front
Battery Activation, Conventional
Battery Charging Procedure, Low Maintenance
Battery Inspection / Removal, Low Maintenance
Battery Installation, Low Maintenance
Battery Load Test
Battery Load Test, Low Maintenance
Battery Off Season Storage
Battery Off Season Storage, Low Maintenance
Battery Open Circuit Voltage (OCV), Low Maintenance
Battery Removal / Inspection, Conventional
Battery Terminals/Bolts
Battery, Maintenance
Body and Steering Torque Values
Brake Bleeding
Brake Burnishing Procedure
Brake Caliper Exploded View
Brake Caliper Removal, Rear
Brake Caliper, Assembly
Brake Caliper, Front
Brake Disc, Front
Brake Disc, Inspection
Brake Light / Work Light Switch Replacement
Brake Light Switch
Brake Noise Troubleshooting
Brake Pad Install, Rear
Brake Pad Removal, Rear
Brake Pad, Rear
Brake Pad, Removal and Installation
Brake System Assembly Views
Brake System Components, Std, Sportsman
Brake System Overview, International
Brake, Master Cylinder Removal
Brake, Rear Auxiliary Brake
Brake, Rear Auxiliary Master Cylinder
Brake, Torque Specifications
Brakes, Inspection
Brakes, Operation Overview
Brakes, Troubleshooting
Bulb Replacement, Front Turn Signal
Bulb Replacement, Rear Tail/Turn Lamp
C
Cam Chain Sprocket, Installation
Cam Chain Tensioner, Installation
Cam Chain Tensioner, Removal / Inspection
Cam Chain, Installation
Camshaft Timing
Camshaft, Inspection
Camshaft, Removal
Carburetor (BST34) Assembly View
Carburetor Jetting
Carburetor Operation
Carburetor Venting
Carburetor, Air/Fuel Ratio
Carburetor, Assembly
Carburetor, Choke System
Carburetor, Cleaning
Carburetor, Disassembly
Carburetor, Float Adjustment
Carburetor, Float System
Carburetor, Idle System
Carburetor, Inspection
Carburetor, Jet Needle
Carburetor, Main System
Carburetor, Needle Jet
Carburetor, Operation
Carburetor, Pilot Screw
Carburetor, Throttle Opening vs Fuel Flow
Charging Procedure
Charging System – Break Even Test
Charging System Flowchart
Choke System
Circuit Breaker
Clutch Alignment
Combustion Chamber
Communication Problems, Digital Wrench
Compression Test
Connector, Trailer
Control Arm Bracket Mounts
Controls, Inspection
Conversion Table
Coolant Sensor Test
Coolant, Level Inspection
Cooling System – Radiator Level
Cooling System Specifications
Cooling System, Maintenance
Counter Balance Shaft, Removal
Crankcase Breather Filter, Service
Crankcase, Assembly
Crankcase, Disassembly
Crankcase, Inspection
Crankcase, Separation
Crankshaft Position Sensor (CPS)
Crankshaft Position Sensor Gap
Crankshaft Straightening
Crankshaft, Removal
Current Draw – Key Off Test
CV Boot Inspection
CV Boot, Inspection
CV Boot, Replacement
CV Carburetor System Function
CV Shaft Service
CV Shaft, Exploded View
CV Shaft, Front
CV Shaft, Rear
Cylinder Head Assembly View
Cylinder Head, Assembly
Cylinder Head, Disassembly
Cylinder Head, Inspection
Cylinder Head, Installation
Cylinder Head, Removal
Cylinder Honing
Cylinder, Inspection
Cylinder, Installation
Cylinder, Removal
D
Dampener Replacement, Seat
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes
Diagnostic Mode, EFI System
Digital Wrench
Engine Controller Reprogramming
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Drive Belt, Deflection
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Remove/Install
Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Spring
Driven Clutch Service (Removable Helix)
Driven Clutch, Assembly
Driven Clutch, Disassembly / Inspection
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
EBS Drive Clutch Service
EBS Exploded View
ECU Replacement
EFI Circuit Diagrams
EFI Operation Overview
EFI Priming / Starting Procedure
EFI, Component Locations
EFI, Crankshaft Position Sensor (CPS)
EFI, Diagnostic Codes
EFI, Engine Temperature Sensor
EFI, Fuel Injector
EFI, Fuel Pressure Regulator
EFI, Idle Air Control
EFI, Intake Air Temperature Sender
EFI, MAP Sensor
EFI, Service Notes
EFI, Special Tools
EFI, Throttle Position Sensor
Electrical Service Notes
Electrical, Break-out Diagrams
Electrical, Service Notes
Electrical, Special Tools
Electronic Control Unit (ECU)
Engine Assembly Views
Engine Controller Reprogramming
Engine Disassembly
Engine Installation Notes
Engine Oil, Inspection
Engine Reassembly
Engine Removal
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Lubrication Requirements
Engine, Oil and Filter Change
Engine, Oil Pump Priming
Engine, Service Data
Engine, Service Data (400 HO)
Engine, Valve Clearance / Adjustment
ETC Operation Test
Exhaust, Information
Exploded View, CV Shaft
F
Fan Control Circuit Operation
Fan Control Circuit Operation / Testing
Fan Motor Current Draw
Final Drive Torque Specifications
Flasher Driver Breakout
Flywheel, Installation
Flywheel, Removal
Foot Well Removal / Installation
Frame Mounts
Front Cab Removal / Installation
Front Cover Removal / Installation
Front CVAxle Installation
Front CV Axle Removal
Front Gearcase – Back Lash Pad Adjustment
Front Gearcase Coil Resistance
Front Gearcase Lubrication
Front Gearcase, Active Descent Control Assembly View
Front Gearcase, Diagnoses
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation
Front Gearcase, Reassembly
Front Gearcase, Reassembly / Inspection
Front Gearcase, Removal
Front Hub, Assembly
Front Hub, Disassembly
Fuel Filter
Fuel Filter, Replacement
Fuel Injector
Fuel Level Test
Fuel Lines
Fuel Pressure Regulator
Fuel Pump / Tank Assembly
Fuel Pump Replacement
Fuel Pump, Testing
Fuel Sender Test
Fuel System Diagnostics
Fuel System Special Tools
Fuel System Troubleshooting
Fuel System, EFI Circuit Diagrams
Fuel System, Inspection
Fuel Tank Location
Fuses
Fuses, Trailer Connector
G
Gear Position Indicator Switch Test
Gear Selector Removal
Gearcase, ADC Hydraulic Fluid Change
Gearcase, Front Capacity and Fluid Type
Guided Diagnostics
H
Handlebar Block Installation Procedure
Head Lamp/Tail Lamp, Sportsman 500 EFI TRACTOR
Headlamp Switch Test
Headlight Housing Replacement
Headlight Pod Exploded View
High Beam Bulb Replacement
High Beam Headlight Adjustment
Hydraulic Brake System Operation Overview
I
Idle Air Control
Ignition System
Ignition System Troubleshooting
Inner Plunging Joint / Boot Replacement
Instrument Cluster (Speedometer) Overview
Instrument Cluster Diagnostic Mode
Instrument Cluster Overview
Instrument Cluster, Setting New Service Interval
Intake Air Temperature Sender
J
Jetting, Specifications
K
Key, Reprogramming Authorization
Keys, Replacement
L
Low Beam Headlight Adjustment
Low Maintenance Battery Charging
Low Maintenance Battery Info
Lower Headlamp Housing Removal
Lower Headlamp Removal
M
Maintenance Chart
Maintenance, General Information
Maintenance, Service Products and Lubricants
MAP Sensor
Mechanical Seal, Installation
Mechanical Seal, Removal (engine disassembled)
Mechanical Seal, Removal (engine installed)
Metric Bolt Torque Specification
Mikuni Jet Part Numbers
Misc Tables
N
Needle and Seat, Leakage Test
O
Oil Flow
Diagram
Overview
Oil Pressure Test, Engine
Oil Pump, Assembly
Oil Pump, Removal
One-Way Valve
One-Way Valve, Installation
Outer CV Joint / Boot Replacement
P
Paint Codes
Pilot System
Piston Identification
Piston Ring, Installation
Piston-to-Cylinder Clearance
Piston, Inspection
Piston, Installation
Piston, Removal
Piston, Ring Installed Gap
Pod, Indicator Replacement
Pod, Switch Replacement
Pre-ride Checklist
Preload Adjustment, Seat
Propshaft, Removal
Publication Numbers
PVT Ducting
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Button to Tower Clearance
PVT, Drive Clutch Disassembly
PVT, Drive Clutch Exploded View
PVT, Drive Clutch Reassembly
PVT, Drive Clutch Spider Removal
PVT, Driven Clutch Assembly (Removable Helix)
PVT, Driven Clutch Bushing Service (Removable Helix)
PVT, Driven Clutch Disassembly (Removable Helix)
PVT, Moveable Sheave Inspection
R
Rear Stabilizer Mounts
Rear Suspension Assembly
Recoil Housing, Draining / Inspection
Recoil, Reassembly
Recoil, Removal
Reflash Authorization
Relays
Reprogramming Authorization
Rocker Arm, Assembly
Rocker Arm, Inspection
S
Seat, Dampener Replacement
Seat, Height Adjustment
Seat, Preload Adjustment
Shift Linkage Inspection
Side Panel Removal
Software Version
Solenoid Test, Speed Control
Spark Plug, Inspection / Replacement
Special Tools
Special Tools, Body & Steering
Special Tools, Clutching
Special Tools, EFI
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Speed Sensor
Specific Gravity Test, Conventional Battery
Specification, Brake Disc Service Limit
Specification, Brake Disc Thickness
Specification, Brake Pad Thickness
Specification, Cylinder Compression
Specification, Differential Solenoid Resistance
Specification, Differential Solenoid Torque
Specification, Fuel Pump Pressure
Specification, Oil and Filter
Specification, Spark Plug Gap
Specification, Speed Sensor Bolt Torque
Specification, Transmission Silent Chain Length
Specification, Valve Clearance
Specifications, Body and Steering Torque Values
Specifications, Brake Component Service Limits
Specifications, Brake Component Torque Values
Specifications, Final Drive Torque Values
Specifications, Front Gearcase Lubrication Type / Capacity
Specifications, Vehicle
Speed Control, Air Control Body
Speed Control, Breakout Diagram
Speed Control, Operation Overview
Speed Control, Solenoid Replacement
Speed Sensor
Speedometer Installation
Speedometer Removal
Speedometer Troubleshooting Tests
Standard Bolt Torque Specification
Starter Armature Testing
Starter Assembly View
Starter Brush Inspection / Replacement
Starter Drive
Starter Drive, Removal
Starter Lockout, Troubleshooting
Starter Motor Dissassembly / Replacement
Starter Reassembly / Installation
Starter System Flow Chart
Steering A-Arm Exploded View
Steering Lock, Exploded View
Steering Post Assembly
Steering Post Removal
Steering Torque Values
Steering, Inspection
Strut Assembly
Strut Cartridge Replacement, Front
Suspension, Inspection
T
Tap/Drill Sizes
Thermostat, Installation
Throttle Cable
Throttle Position Sensor
Throttle Position Sensor Initialization
Throttle Position Sensor Replacement
Throttle, Linkage Inspection
Tie Rod, Inspection
Torque Patterns, Engine Fasteners
Torque Specifications, Clutching
Torque Specifications, Engine
Trail Boss Emissions System
Trailer, Connector and Fuses
Transmission
Control Arm Bracket Mounts
Frame Mounts
Rear Stabilizer Mounts
Upper Frame Mount
Transmission ID Information
Transmission, Assembly
Transmission, Assembly View
Transmission, Disassembly
Transmission, Install
Transmission, Output Shaft Backlash Procedure
Transmission, Removal
Transmission, Special Tools
Troubleshooting
Troubleshooting Diagrams, Electrical
Troubleshooting, Clutching
Troubleshooting, EFI Circuit Diagrams
Troubleshooting, Engine
TRS Switch Operation
U
U-joint, Disassembly and Assembly
Upper Frame Mount
V
Valve Clearance Adjustment
Valve Sealing Test
Valve Seat Reconditioning
Valve, Inspection
Vehicle Information
VIN Number
Version, Software
VIN
VIN Number
Voltage Drop Test
W
Wheel Alignment
Wheels, Removal
Wheels, Tire Pressure
Wheels, Torque Table
Wire Diagrams, Electrical