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Do not over tighten the wheel nuts. Do not allow the lip of the seals to turn in- side out or fold. The needle and seat should hold pressure indefinitely. Remove output shaft assembly, large shim, and thrust button with its small shim. Install center shaft brake disc shaft bushing using small end of bushing installation tool. Battery Installation – projex inbox.

Polaris Sportsman 400 Manuals

Working from the top, insert adapter number ten onto puller. Install outer yoke, aligning marks made before disassembly.

Use either of the following methods to remove and install a new garter spring. Install access plate with notch to front as shown, torque screws to specification. See illustration at right. Inspect the bore for nicks, scratches or wear. When riding in extremely dusty conditions re- placement will be required more often. Decimal Equivalents – projex inbox.


Front Caliper Mounting Bolt Torque 18 ft. Valve seat width and point of contact on the valve face is very important for proper sealing.

If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Inspect the surfaces closely for nicks, burrs or damage. Inspect ramp buttons in the moveable sheave and replace if worn. Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system.

Refer to Clutch Chapter. Apply Loctite retaining compound to the back side of new bushing. While maintaining lever pressure, open bleeder screw. Carburetor Assembly – projex inbox. Awd Operation Overview – projex inbox. Awd Front Drive Axle Removal – projex inbox. Remove polarks from rubber boot s using the proper boot clamp pliers.


Install shaft with bearing in front output housing. Cam Chain Tensioner Installation – projex inbox. One Way Valve polariz projex inbox.

Pull cam chain tensioner plunger outward to the end of its travel. Clamp gear shift selector body lightly in a soft jawed vise. Remove cover bolts evenly in a cross pattern, and remove cover plate. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase.

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Compression Test, Engine Mounts – projex inbox. Inspect PVT inner cover-to engine seal.

Remove ignition timing inspection plug from recoil housing. Oil Pump Assembly – projex inbox. Remove the check plug.