Polaris Sportsman 450 2006 2007 2008 Workshop Service Manual
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Polaris Sportsman 450 2006 2007 2008 Workshop Service Manual
FOREWORD:
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
TABLE OF CONTENTS:
Polaris Sportsman 450 2006 2007 2008 Workshop Service Manual
MODEL NUMBER INFORMATION 12
MODEL NUMBER 12
ENGINE DESIGNATION NUMBERS 12
VEHICLE IDENTIFICATION NUMBER (VIN) 12
TRANSMISSION ID LOCATION 12
ENGINE AND MACHINE SERIAL NUMBERS 12
PUBLICATIONS13
PAINT CODES 13
REPLACEMENT KEYS13
SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON14
SPORTSMAN X2 ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON15
2007 SPORTSMAN 45016
MODEL NUMBER: A07MH46AA, AZ 16
2007 SPORTSMAN 500 EFI18
MODEL NUMBER: A07MH50AX, AY, AZ / A07MN50AQ, AF / A07MH50FC18
2007 SPORTSMAN X-2 500 EFI 110
MODEL NUMBER: A07TH50AU, AZ / A07TN50AF, AQ / A07TH50EA 110
MISC NUMBERS/CHARTS 112
STANDARD TORQUE SPECIFICATIONS 112
SAE TAP DRILL SIZES 113
METRIC TAP DRILL SIZES 113
DECIMAL EQUIVALENTS113
CONVERSION TABLE114
GLOSSARY OF TERMS 115
MAINTENANCE23
PERIODIC MAINTENANCE CHART 23
MAINTENANCE CHART KEY 23
PERIODIC MAINTENANCE CHART 24
LUBRICATION / FLUIDS 27
SPORTSMAN COMPONENT LOCATIONS 27
SPORTSMAN X2 COMPONENT LOCATIONS28
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS 29
POLARIS LUBRICANT SYMBOL IDENTIFICATION 210
PRE-RIDE / DAILY INSPECTION210
LUBRICATION COMPONENTS 211
FRONT GEARCASE LUBRICATION 212
TRANSMISSION LUBRICATION 213
ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE 214
VEHICLE INSPECTION 214
SHIFT LINK ROD INSPECTION 214
THROTTLE INSPECTION215
THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT 215
FUEL SYSTEM 216
FUEL LINES 216
VENT LINES 216
FUEL FILTER 217
COMPRESSION TEST 217
ENGINE MOUNTS217
SPARK PLUG218
ACTIVE DESCENT CONTROL (ADC) RESERVOIR LEVEL218
BATTERY MAINTENANCE 218
LIQUID COOLING SYSTEM OVERVIEW219
COOLANT STRENGTH / TYPE 219
COOLING SYSTEM HOSES 219
RADIATOR/GRILL SCREEN 219
COOLING SYSTEM PRESSURE TEST 220
COOLANT LEVEL INSPECTION 220
RADIATOR COOLANT LEVEL INSPECTION220
AIR FILTER/PRE-FILTER SERVICE 220
AIR BOX SEDIMENT TUBE 221
BREATHER FILTER INSPECTION 222
BREATHER HOSE222
RECOIL HOUSING 222
ENGINE OIL LEVEL 223
OIL AND FILTER CHANGE 223
OIL PUMP PRIMING PROCEDURE 225
VALVE CLEARANCE 225
INTAKE VALVE CLEARANCE ADJUSTMENT 226
EXHAUST VALVE CLEARANCE ADJUSTMENT226
STEERING226
TIE ROD END/STEERING INSPECTION227
CAMBER AND CASTER 227
WHEEL ALIGNMENT227
TOE ALIGNMENT ADJUSTMENT228
EXHAUST PIPE 228
BRAKE SYSTEM INSPECTION 229
BRAKE PAD INSPECTION 230
HOSE/FITTING INSPECTION230
SPECIFICATIONS 33
TORQUE SPECIFICATIONS 33
SPECIAL TOOLS 33
ENGINE FASTENER TORQUE PATTERNS 33
ENGINE SERVICE DATA 34
ENGINE SERVICE DATA 35
GENERAL ENGINE SERVICE 36
PISTON IDENTIFICATION36
COOLING SYSTEM SPECIFICATIONS 36
COOLING SYSTEM37
ACCESSIBLE COMPONENTS38
ENGINE REMOVAL (TYPICAL)38
ENGINE INSTALLATION NOTES 39
CYLINDER HONE SELECTION/ HONING PROCEDURE39
HONING TO OVERSIZE 39
CLEANING THE CYLINDER AFTER HONING 310
CRANKSHAFT STRAIGHTENING 310
ENGINE LUBRICATION – EH 50PL 311
OIL PRESSURE TEST – EH 50PL311
OIL PUMP PRIMING PROCEDURE 311
OIL FLOW – EH50PL 311
EH50PL OIL FLOW DIAGRAM 312
EH50PL ENGINE EXPLODED VIEWS 313
ENGINE DISASSEMBLY 314
CAM CHAIN TENSIONER/ROCKER ARM/ CAMSHAFT REMOVAL314
CAM CHAIN TENSIONER INSPECTION314
ROCKER ARM/SHAFT INSPECTION315
CAMSHAFT REMOVAL 316
AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION317
AUTOMATIC COMPRESSION RELEASE INSTALLATION 318
CAMSHAFT INSPECTION 318
CYLINDER HEAD REMOVAL319
CYLINDER HEAD EXPLODED VIEW, EH50PL 320
CYLINDER HEAD INSPECTION 321
CYLINDER HEAD WARP321
CYLINDER HEAD DISASSEMBLY 321
VALVE INSPECTION 322
COMBUSTION CHAMBER 323
VALVE SEAT RECONDITIONING323
CYLINDER HEAD ASSEMBLY 326
VALVE SEALING TEST 326
VALVE CLEARANCE ADJUSTMENT326
CYLINDER/PISTON REMOVAL AND INSPECTION 327
PISTON REMOVAL 328
CYLINDER INSPECTION328
PISTON-TO-CYLINDER CLEARANCE 329
PISTON/ROD INSPECTION 329
PISTON RING INSTALLED GAP 330
CRANKCASE DISASSEMBLY330
STARTER DRIVE REMOVAL/INSPECTION 331
FLYWHEEL/STATOR REMOVAL/INSPECTION 331
CAM CHAIN/TENSIONER BLADE 332
ONE WAY VALVE REMOVAL332
CRANKCASE SEPARATION 333
32
ENGINE
OIL PUMP REMOVAL/INSPECTION333
OIL PUMP ASSEMBLY 334
COUNTER BALANCER SHAFT REMOVAL/INSPECTION 334
CRANKSHAFT REMOVAL/INSPECTION335
CRANKCASE BEARING INSPECTION 336
PUMP SHAFT OIL SEAL/WATER PUMP MECHANICAL SEAL REMOVAL336
CRANKCASE INSPECTION 336
BEARING INSTALLATION 337
END PLAY INSPECTION/ADJUSTMENT337
CRANKSHAFT END PLAY ADJUSTMENT 337
COUNTER BALANCER SHAFT END PLAY ADJUSTMENT338
OIL PUMP SHAFT END PLAY ADJUSTMENT 339
ENGINE REASSEMBLY 340
PUMP SHAFT OIL SEAL INSTALLATION 340
CRANKSHAFT/COUNTER BALANCE/OIL PUMP INSTALLATION 340
CRANKCASE ASSEMBLY 341
WATER PUMP MECHANICAL SEAL INSTALLATION 341
WATER PUMP MECHANICAL SEAL REMOVAL – ENGINE INSTALLED 341
ONE WAY VALVE INSTALLATION 342
CAM CHAIN DRIVE SPROCKET INSTALLATION 343
TENSIONER BLADE INSTALLATION343
PISTON RING INSTALLATION 343
PISTON INSTALLATION 344
CYLINDER INSTALLATION 344
CYLINDER HEAD INSTALLATION 345
CAM CHAIN/CAMSHAFT INSTALLATION 345
CAMSHAFT TIMING 346
CAMSHAFT TIMING 348
CAM CHAIN TENSIONER INSTALLATION 349
STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION349
ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION 350
THERMOSTAT INSTALLATION 350
OIL PIPES350
RECOIL351
RECOIL DISASSEMBLY/INSPECTION 351
RECOIL ASSEMBLY 352
TROUBLESHOOTING353
SPARK PLUG FOULING 353
ENGINE 353
COOLING SYSTEM 354
SPECIAL TOOLS 45
PART NUMBERS / DESCRIPTIONS 45
EFI SERVICE NOTES 47
GENERAL SERVICE INFORMATION 47
EFI SYSTEM EXPLODED VIEW 48
EFI SYSTEM49
COMPONENT LOCATIONS/IDENTIFICATION 49
FUEL TANK410
EXPLODED VIEW410
ELECTRONIC FUEL INJECTION 410
GENERAL INFORMATION 410
EFI OPERATION OVERVIEW410
INITIAL PRIMING / STARTING PROCEDURE 411
FUEL LINES 411
QUICK CONNECT REMOVAL/INSTALLATION 411
ELECTRONIC CONTROL MODULE (ECM) 412
OPERATION OVERVIEW412
ECM REPLACEMENT412
ECM SERVICE 412
FUEL PUMP ASSEMBLY 413
OPERATION / TESTING 413
FUEL PUMP TEST413
FUEL PUMP / TANK ASSEMBLY REPLACEMENT 414
FUEL PRESSURE REGULATOR 415
GENERAL INFORMATION 415
FUEL FILTERS416
GENERAL INFORMATION 416
FUEL INJECTOR 416
GENERAL INFORMATION 416
CRANKSHAFT POSITION SENSOR (CPS) 417
GENERAL INFORMATION 417
MANIFOLD AIR PRESSURE SENSOR (MAP)418
OPERATION OVERVIEW418
MAP SENSOR TEST 418
MAP SENSOR REPLACEMENT 418
INTAKE AIR TEMPERATURE SENSOR (IAT)419
OPERATION OVERVIEW419
INTAKE AIR TEMPERATURE SENSOR TEST 419
INTAKE AIR TEMPERATURE SENSOR REPLACEMENT 419
IDLE AIR CONTROL (IAC)419
GENERAL INFORMATION 419
THROTTLE POSITION SENSOR (TPS) 420
OPERATION OVERVIEW420
THROTTLE POSITION SENSOR TEST 420
THROTTLE POSITION SENSOR REPLACEMENT 421
THROTTLE POSITION SENSOR (TPS) INITIALIZATION 421
ENGINE TEMPERATURE SENSOR 422
GENERAL INFORMATION 422
ENGINE TEMPERATURE SENSOR TEST 422
ENGINE TEMPERATURE SENSOR REPLACEMENT 422
44
FUEL INJECTION
FUEL SYSTEM TROUBLESHOOTING 423
FUEL STARVATION / LEAN MIXTURE 423
EFI DIAGNOSTICS USING ‘BLINK CODES’ 424
BLINK CODES – OPERATION 424
TROUBLESHOOTING DIAGRAMS 426
EFI CIRCUIT – POWER ON 426
EFI CIRCUIT – CRANK POSITION SENSOR426
EFI CIRCUIT – FUEL PUMP 427
EFI CIRCUIT – IGNITION COIL 427
EFI CIRCUIT – IDLE AIR CONTROL 428
EFI CIRCUIT – THROTTLE POSITION SENSOR428
EFI CIRCUIT – MANIFOLD ABSOLUTE PRESSURE SENSOR 429
EFI CIRCUIT – ENGINE COOLANT TEMPERATURE 429
EFI CIRCUIT – AIR TEMPERATURE SENSOR 430
EFI CIRCUIT – MALFUNCTION INDICATOR LIGHT430
GENERAL INFORMATION AND SPECIFICATIONS 432
SPECIAL TOOLS 432
CARBURETOR JETTING432
MIKUNI JET PART NUMBERS 432
CARBURETOR SPECIFICATIONS 432
CARBURETION 433
BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 433
BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 434
CV CARBURETOR SYSTEM FUNCTION435
CARBURETOR VENTING435
MIKUNI CV CARB OPERATION 435
STARTER SYSTEM (CHOKE OR ENRICHMENT) 436
PILOT (IDLE AND SLOW) SYSTEM 436
MAIN SYSTEM 437
FLOAT SYSTEM 437
PILOT SCREW438
AIR/FUEL MIXTURE RATIO 438
JET NEEDLE 439
NEEDLE JET 439
THROTTLE OPENING VS FUEL FLOW439
CARBURETOR DISASSEMBLY – MIKUNI CV 439
CARBURETOR CLEANING 440
CARBURETOR INSPECTION441
CARBURETOR ASSEMBLY 441
FLOAT HEIGHT ADJUSTMENT 442
NEEDLE AND SEAT LEAKAGE TEST 442
FUEL LEVEL TEST 443
FUEL TANK/FUEL DELIVERY SYSTEM 444
FUEL SYSTEM EXPLODED VIEW 444
FUEL PUMP 445
FUEL PUMP TESTING 445
FUEL PUMP DISASSEMBLY445
FUEL PUMP INSPECTION AND REASSEMBLY446
FUEL FILTER REPLACEMENT 446
FUEL GAUGE SENDING UNIT 446
SENDING UNIT REMOVAL 446
TESTING 447
SENDING UNIT INSTALLATION 447
TROUBLESHOOTING447
FUEL STARVATION/LEAN MIXTURE 447
GENERAL INFORMATION 52
TORQUE SPECIFICATIONS 52
SPECIAL TOOLS 52
DECAL REPLACEMENT 52
PLASTIC INSERT REMOVAL / INSTALLATION 53
BODY 54
SIDE PANEL REMOVAL 54
FRONT COVER REMOVAL / INSTALLATION54
FOOT WELL REMOVAL / INSTALLATION55
X2 FOOT WELL REMOVAL / INSTALLATION55
FRONT STORAGE REMOVAL56
FRONT STORAGE INSTALLATION 58
SPORTSMAN REAR RACK REMOVAL / INSTALLATION58
FRONT CAB/FENDER REMOVAL/INSTALLATION 59
SPORTSMAN REAR CAB / FENDER REMOVAL / INSTALLATION510
X2 REAR QUARTER PANEL REMOVAL / INSTALLATION 510
SPORTSMAN REAR STORAGE REMOVAL / INSTALLATION 511
RADIATOR SCREEN REMOVAL511
SPORTSMAN BODY ASSEMBLY EXPLODED VIEW 512
X2 BODY ASSEMBLY EXPLODED VIEW 513
BODY RACK EXPLODED VIEWS514
HEADLIGHT POD EXPLODED VIEW515
STEERING516
HANDLEBAR BLOCK INSTALLATION PROCEDURE 516
STEERING / A-ARM EXPLODED VIEW 517
A-ARM REPLACEMENT 518
BALL JOINT REPLACEMENT519
STEERING POST REMOVAL520
STEERING POST ASSEMBLY 520
SUSPENSION 520
FRONT STRUT CARTRIDGE REPLACEMENT 520
STRUT ASSEMBLY 521
SPORTSMAN REAR SUSPENSION ASSEMBLY522
X2 REAR SUSPENSION EXPLODED VIEW 523
X2 TORSION BAR EXPLODED VIEW 524
X2 CARGO BOX 525
EXPLODED VIEW525
REMOVAL / INSTALLATION 526
X2 SEAT ASSEMBLY 528
EXPLODED VIEWS 528
X2 SEAT OPERATION – CONFIGURING CARGO BOX FOR PASSENGER RIDING 529
DRIVER SEAT BACKREST REMOVAL / INSTALLATION 530
PASSENGER SEAT BACKREST REMOVAL / INSTALLATION 530
SPECIAL TOOLS AND SPECIFICATIONS62
SPECIAL TOOLS 62
COMPONENT FASTENER TORQUES62
PVT EXPLODED VIEWS 63
PVT SEALING AND DUCTING COMPONENTS 63
DRIVE CLUTCH EXPLODED VIEW 63
ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW 64
EBS DRIVEN CLUTCH EXPLODED VIEW65
PVT SYSTEM 66
PVT OPERATION OVERVIEW66
DRIVE CLUTCH OPERATION66
DRIVEN CLUTCH OPERATION 66
EBS CLUTCH OPERATION 67
PVT MAINTENANCE / INSPECTION 67
DRIVE CLUTCH SPRING 68
OPTIONAL SHIFT WEIGHTS 69
PVT DRYING 610
PVT DISASSEMBLY 610
PVT INSTALLATION 611
DRIVE BELT REMOVAL / INSPECTION 612
DRIVE BELT INSTALLATION613
CLUTCH ALIGNMENT614
CLUTCH OFFSET614
EBS DRIVE CLUTCH SERVICE 615
DRIVE CLUTCH DISASSEMBLY615
SPIDER REMOVAL 615
BUTTON TO TOWER CLEARANCE INSPECTION 617
SHIFT WEIGHT INSPECTION617
DRIVE CLUTCH INSPECTION 617
MOVEABLE SHEAVE BUSHING INSPECTION 618
DRIVE CLUTCH BUSHING SERVICE 618
ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) 620
DRIVE CLUTCH REASSEMBLY 620
EBS DRIVEN CLUTCH SERVICE622
DRIVEN CLUTCH DISASSEMBLY 622
DRIVEN CLUTCH BUSHING REMOVAL/INSTALLATION 624
EBS DRIVEN CLUTCH REASSEMBLY 625
STANDARD DRIVE CLUTCH 628
DRIVE CLUTCH DISASSEMBLY628
SPIDER REMOVAL 629
BUTTON TO TOWER CLEARANCE INSPECTION 630
SHIFT WEIGHT INSPECTION630
DRIVE CLUTCH REASSEMBLY 631
SHEAVE / BUSHING INSPECTION 632
STANDARD DRIVEN CLUTCH 633
DISASSEMBLY 633
INSPECTION 633
ASSEMBLY 634
PVT TROUBLESHOOTING 635
OVERHEATING 635
PROBLEM, CAUSE AND REMEDY CHART 636
SPECIFICATIONS 72
TORQUE TABLE 72
SPECIAL TOOLS 72
GEARCASE FLUID / CAPACITY 72
FRONT DRIVE AXLE 72
REMOVAL 72
INSTALLATION74
FRONT DRIVE SHAFT (CV) BOOT74
INSPECTION 74
REPLACEMENT 74
FRONT HUB76
DISASSEMBLY76
ASSEMBLY76
PROP SHAFT – FRONT OR REAR77
REMOVAL AND INSTALLATION 77
U-JOINT77
DISASSEMBLY77
ASSEMBLY78
DRIVE AXLE EXPLODED VIEWS710
DRIVE SHAFTS AND PROPSHAFTS710
FRONT GEARCASE – CENTRALIZED HILLIARD (STANDARD MODELS) 711
EXPLODED VIEW (STANDARD MODELS) 711
OPERATION 712
GEARCASE REMOVAL 712
DISASSEMBLY / INSPECTION 713
REASSEMBLY / INSPECTION 717
SETTING RING GEAR BACKLASH 718
FRONT GEARCASE DIAGNOSIS719
GEARCASE INSTALLATION 720
FRONT GEARCASE – ACTIVE DESCENT CONTROL (DELUXE MODELS)721
ADC GEARCASE EXPLODED VIEW (DELUXE MODELS) 721
OPERATION 722
ADC COIL TESTING 723
ADC DIFFERENTIAL HYDRAULIC CIRCUIT BLEEDING 723
DISASSEMBLY / INSPECTION 724
ADC GEARCASE PISTON REPLACEMENT PROCEDURE728
ASSEMBLY 730
REAR HUB733
REMOVAL733
DISASSEMBLY 734
ASSEMBLY 735
INSTALLATION 735
REAR DRIVE (CV) SHAFT736
REMOVAL736
SERVICE 737
CV BOOT REPLACEMENT 738
INSTALLATION 739
DRIVE SHAFT AND CV JOINT HANDLING TIPS740
TRANSMISSION – GENERAL 82
MOUNTING EXPLODED VIEW82
TORQUE SPECIFICATIONS 83
SPECIAL TOOLS 83
LUBRICATION 83
GEAR SELECTOR REMOVAL83
TRANSMISSION REMOVAL 83
TRANSMISSION INSTALLATION 85
TROUBLESHOOTING CHECKLIST 86
TRANSMISSION SERVICE87
EXPLODED VIEW 87
TRANSMISSION DISASSEMBLY 89
TRANSMISSION ASSEMBLY814
TRANSMISSION FRONT OUTPUT SHAFT BACKLASH PROCEDURE815
SPECIFICATIONS 92
TORQUE TABLE 92
COMPONENT SERVICE LIMITS 92
BRAKE SYSTEM EXPLODED VIEWS 93
X2 SYSTEM COMPONENT EXPLODED VIEW 93
SPORTSMAN SYSTEM COMPONENT EXPLODED VIEW 94
BRAKE CALIPER EXPLODED VIEWS 95
SPORTSMAN AND X2 FRONT CALIPER ASSEMBLY 95
X2 REAR CALIPER ASSEMBLY 95
SPORTSMAN REAR CALIPER ASSEMBLY 96
HYDRAULIC BRAKE SYSTEM 96
OPERATION OVERVIEW 96
BRAKE NOISE TROUBLESHOOTING97
BRAKE BLEEDING / FLUID CHANGE97
FRONT MASTER CYLINDER 99
REMOVAL 99
INSTALLATION99
FRONT BRAKES 910
PAD REMOVAL 910
ASSEMBLY 911
BRAKE BURNISHING PROCEDURE912
FRONT BRAKE DISC 912
INSPECTION 912
REMOVAL / REPLACEMENT913
FRONT CALIPER 914
REMOVAL914
INSPECTION 915
REASSEMBLY915
INSTALLATION 916
REAR BRAKE PAD917
X2 PAD REMOVAL 917
X2 PAD INSTALLATION 918
SPORTSMAN REAR PAD REMOVAL919
SPORTSMAN REAR PAD INSTALLATION 920
BRAKE BURNISHING PROCEDURE920
X2 REAR CALIPER921
REMOVAL921
INSPECTION 922
REASSEMBLY922
SPORTSMAN REAR CALIPER 923
REMOVAL AND INSPECTION 923
ASSEMBLY 924
REAR BRAKE DISC 925
INSPECTION 925
REAR MASTER CYLINDER 926
X2 EXPLODED VIEW926
OVERVIEW 927
X2 REAR MASTER CYLINDER REMOVAL AND INSTALLATION 927
SPORTSMAN REAR MASTER CYLINDER REMOVAL / INSTALLATION 928
PEDAL REMOVAL AND INSTALLATION929
TROUBLESHOOTING929
BRAKES SQUEAL929
POOR BRAKE PERFORMANCE929
LEVER VIBRATION 929
CALIPER OVERHEATS (BRAKES DRAG) 929
BRAKES LOCK 929
GENERAL INFORMATION103
SPECIAL TOOLS 103
IGNITION SYSTEM / BASIC ELECTRICAL COMPONENTS103
ELECTRICAL SERVICE NOTES 104
TROUBLESHOOTING104
POWER DISTRIBUTION MODULES (PDM) 105
SPORTSMAN EFI OVERVIEW 105
SPORTSMAN 450 OVERVIEW 1010
INSTRUMENT CLUSTER1013
OVERVIEW 1013
INSTRUMENT CLUSTER DIAGNOSTIC MODE1014
SETTING A NEW SERVICE INTERVAL1016
EFI DIAGNOSTIC MODE 1017
SPEEDOMETER REMOVAL1018
SPEEDOMETER INSTALLATION 1018
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING1019
TEST 1 – NO ALL WHEEL DRIVE 1019
TEST 2 – NO SPEEDOMETER DISPLAY 1020
TEST 3 – NO REVERSE SPEED LIMIT 1020
TEST 4 – NO AWD HUB SAFETY LIMIT1021
TEST 5 – REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR1022
TEST 6 – WHEEL SPEED SENSOR1022
TEST 7 – FUEL GAUGE DISPLAY NOT WORKING1023
TEST 8 – SHIFT INDICATOR NOT WORKING 1023
ACTIVE DESCENT CONTROL (ADC) COIL1024
OPERATION OVERVIEW 1024
DIAGNOSING SYSTEM FAILURES1024
ALL WHEEL DRIVE (AWD) COIL1024
OPERATION OVERVIEW 1024
DIAGNOSING SYSTEM FAILURES1024
COOLING SYSTEM COMPONENTS1025
FAN CONTROL CIRCUIT OPERATION1025
FAN CONTROL BYPASS TEST1025
FAN MOTOR CURRENT DRAW TEST 1025
COOLANT TEMPERATURE SENSOR 1026
GEAR POSITION INDICATOR SWITCH1026
TEST DIAGRAM1026
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH 1027
OPERATION OVERVIEW 1027
ETC TEST 1027
IGNITION SYSTEM 1028
OVERVIEW 1028
COMPONENTS OF EFI ALTERNATOR AND DC / CDI IGNITION SYSTEM 1029
EFI IGNITION SYSTEM TESTING FLOW CHART 1030
CRANKSHAFT POSITION SENSOR GAP 1031
IGNITION TROUBLESHOOTING 1031
IGNITION OUTPUT TEST USING GAP TESTER 1031
CHARGING SYSTEM1032
CURRENT DRAW – KEY OFF 1032
BREAK EVEN TEST1032
ALTERNATOR OUTPUT TEST 1032
CHARGING SYSTEM TESTING DIAGRAMS 1034
DIFFERENTIAL SOLENOID 1036
TESTING1036
REPLACEMENT1036
102
ELECTRICAL
LIGHTING1036
HIGH BEAM HEADLIGHT BULB REPLACEMENT 1036
HEADLIGHT HOUSING RELACEMENT1037
HIGH BEAM HEADLIGHT ADJUSTMENT 1038
LOWER HEADLAMP REMOVAL / INSTALLATION1038
LOW BEAM HEADLIGHT ADJUSTMENT 1039
HEADLAMP SWITCH TEST1039
WORK LIGHT SWITCH 1040
BRAKE LIGHT / WORK LIGHT REPLACEMENT 1040
BRAKE LIGHT SWITCH TEST 1041
SPEED SENSOR1042
TESTING1042
REPLACEMENT1042
FUEL SENDER 1042
TESTING1042
ACCESSORY POWER 1043
WIRE CONNECTIONS 1043
STARTER SYSTEM 1044
TROUBLESHOOTING 1044
VOLTAGE DROP TEST 1044
STARTER LOCKOUT TROUBLESHOOTING- EFI MODELS 1044
STARTER LOCKOUT TROUBLESHOOTING- SPORTSMAN 450 1044
STARTER LOCKOUT DIAGRAM- EFI 1045
STARTER LOCKOUT DIAGRAM- SPORTSMAN 450 1045
STARTER MOTOR REMOVAL / DISASSEMBLY 1046
BRUSH INSPECTION / REPLACEMENT 1046
ARMATURE TESTING 1047
STARTER REASSEMBLY 1048
STARTER SOLENOID BENCH TEST 1048
STARTER EXPLODED VIEW 1048
STARTER DRIVE1049
PINION GEAR – ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT1049
STARTER SYSTEM TESTING FLOW CHART 1050
BASIC WINCH WIRING 1051
PRE-WIRED MODELS 1051
TROUBLESHOOTING DIAGRAMS 1052
POWER ON – EFI 1052
START CIRCUIT – EFI 1052
IGNITION COIL – EFI1053
FUEL PUMP – EFI 1053
FAN – EFI1054
CHARGING SYSTEM – EFI 1054
ALL WHEEL DRIVE – EFI 1055
TRANSMISSION SWITCH – EFI1055
REVERSE OVERRIDE – EFI1056
DIFFERENTIAL SOLENOID – X21056
BATTERY1057
BATTERY IDENTIFICATION1057
BATTERY ACTIVATION1057
TERMINAL PREPARATION1058
BATTERY REMOVAL 1058
BATTERY INSTALLATION 1058
OFF SEASON STORAGE 1059
LOW MAINTENANCE BATTERY OFF-SEASON STORAGE 1059
BATTERY TESTING1059
CONVENTIONAL BATTERY OCV – OPEN CIRCUIT VOLTAGE TEST1059
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST 1059
BATTERY LOAD TEST 1060
CHARGING PROCEDURE 1060
LOW MAINTENANCE BATTERY CHECK: 1061
LOW MAINTENANCE BATTERY CHARGING 1061
LOW MAINTENANCE BATTERY – OCV- OPEN CIRCUIT VOLTAGE TEST 1062
LOW MAINTENANCE BATTERY LOAD TEST 1062
LOW MAINTENANCE BATTERY CHARGING PROCEDURE 1062
500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEM 112
OVERVIEW 112
EXPLODED VIEW113
500 EFI INTERNATIONAL / QUADRICYCLE STEERING POST AND LOCK114
STEERING ASSEMBLY EXPLODED VIEW 114
500 EFI QUADRICYCLE EMISSIONS SYSTEM 115
OVERVIEW 115
500 QUADRICYCLE ELECTRICAL116
TURN / HAZARD SIGNAL DIAGRAM116
INDEX DETAILS:
Polaris Sportsman 450 2006 2007 2008 Workshop Service Manual
A
A-Arm Replacement 518
Active Descent Control (ADC) Coil1024
Active Descent Control Gearcase 722
ADC Gearcase Piston Service727
ADC Gearcase, Disassembly / Inspection723
ADC reservoir level inspection 218
Air Filter, Service 220
Alignment, Wheel 227
All Wheel Drive (AWD) Coil 1024
All Wheel Drive and Speedometer Troubleshooting Tests
1019
Alternator / Ignition Components1029
Alternator Output Test 1032
ATV Cleaning and Storage236
B
Ball Joint Replacement, Front519
Battery Activation, Conventional1057
Battery Charging Procedure, Low Maintenance1062
Battery Load Test1060
Battery Load Test, Low Maintenance 1062
Battery Off Season Storage 1059
Battery Off Season Storage, Low Maintenance 1059
Battery Open Circuit Voltage (OCV), Low Maintenance
1062
Battery Removal / Inspection, Conventional1058
Battery Specific Gravity Tes, Conventional 1059
Battery Terminals/Bolts 1058
Battery, Installation 1058
Battery, Maintenance 218
Body and Steering Torque Values 52
Body Assembly Exploded View512, 513
Body Rack Exploded View 514
Brake Bleeding 97
Brake Burnishing Procedure 912
Brake Caliper Exploded View 95
Brake Caliper Removal, Rear 921, 923
Brake Caliper, Assembly 924
Brake Caliper, Front 914
Brake Disc, Front 912
Brake Disc, Inspection925
Brake Light / Work Light Switch Replacement 1040
Brake Light Switch 1041
Brake Noise Troubleshooting 97
Brake Pad Install, Rear920
Brake Pad Removal, Rear 919
Brake Pad, Rear 917
Brake Pad, Removal and Installation 910
Brake System Components, Std, Sportsman 94
Brake System Components, X293
Brake System Exploded View, International 113
Brake System Exploded Views93
Brake System Overview, International112
Brake, Master Cylinder Removal 99
Brake, Rear Auxiliary Brake 928
Brake, Rear Auxiliary Master Cylinder 926
Brake, Torque Specifications 92
Brakes, Inspection229
Brakes, Operation Overview 96
Brakes, Troubleshooting 929
C
Cam Chain Removal 314
Cam Chain Tensioner, Inspection314
Camshaft Removal 316
Camshaft Timing 346
Carburetor (BST34) Exploded View 433
Carburetor Jetting432
Carburetor Operation 435
Carburetor Venting 435
Carburetor, Air/Fuel Ratio 438
Carburetor, Assembly441
Carburetor, Choke System 436
Carburetor, Cleaning 440
Carburetor, Disassembly 439
Carburetor, Float Adjustment442
Carburetor, Float System 437
Carburetor, Idle System 436
Carburetor, Inspection441
Carburetor, Jet Needle439
Carburetor, Main System437
Carburetor, Needle Jet439
Carburetor, Operation435
Carburetor, Pilot Screw 438
Carburetor, Throttle Opening vs Fuel Flow 439
Cargo Box, Removal and Installation526
Charging Procedure 1060
Charging System – Break Even Test1032
Charging System Flow Chart1030, 1034
Choke System436
Clutch Alignment614
Clutch Offset 614
Clutch, Troubleshooting 636
Clutching Chart 16, 18, 110
Component Locations 28
Component Locations, Sportsman27
Compression Test217
Controls, Inspection 231
Conversion Table114
Coolant Sensor Test1026
Coolant, Level Inspection220
Coolant, Recommended Ratio 38
Cooling System Pressure Test 37
Cooling System Specifications36
Cooling System, Maintenance219
Counter Balancer Endplay Adjustment 338
Counter Balancer, Removal and Inspection 334
Crankcase Breather Filter, Service 222
Crankcase Separation333
Crankshaft Endplay Adjustment 337
Crankshaft Position Sensor (CPS)417
IX2
Crankshaft Position Sensor Gap1031
Crankshaft Straightening 310
Crankshaft, Removal and Inspection 335
Current Draw – Key Off Test 1032
CV Boot, Inspection 231
CV Boot, Replacement74
CV Carburetor System Function 435
Cylinder Head Removal 319
Cylinder Head Torque Procedure345
Cylinder Honing 39
Cylinder Installation 344
Cylinder Removal327
D
Decal Replacement52
Diagnostic Codes1017
Diagnostic Mode, EFI System 1017
Differential Solenoid1036
Drive Belt, Installation 613
Drive Belt, Removal/Inspection 612
Drive Clutch Springs 68
Drive Clutch Weights 69
Drive Clutch, Operation 66
Drive Clutch, Standard Service 628
Drive Shaft Boot Inspection 74
Driven Clutch, Operation 66
Driven Clutch, Standard Service 634
E
EBS Drive Clutch Service615
EBS Driven Clutch Service 622
EBS Exploded View 64, 65
EBS, Driven Clutch Operation67
EFI Operation Overview 410
EFI Priming / Starting Procedure411
Electrical Service Notes 104
Electrical, Service Notes 104
Electrical, Special Tools 103
Electronic Control Unit (ECU) 412
Elelctrical, Troubleshooting Diagrams 1052
Engine Diagnostic Codes424
Engine Disassembly 314
Engine Exploded Views 313
Engine Installation Notes 39
Engine Oil, Inspection223
Engine Reassembly 340
Engine Removal 38
Engine Service Data 34
Engine Temperature Sensor 422
Engine Temperature Sensor Replacement 422
Engine Temperature Sensor Test422
Engine, Fastener Torque Patterns 33
Engine, Lubrication Requirements 311
Engine, Oil and Filter Change223
Engine, Oil Pump Priming 225
Engine, Torque Specifications33
Engine, Valve Clearance / Adjustment 225
ETC Operation Test 1027
ETC Switch Operation 1027
F
Fan Control Circuit Operation 1025
Fan Control Circuit Operation / Testing1025
Fan Motor Current Draw1025
Final Drive Torque Specifications 72
Flywheel / Stator Removal331
Foot Well Removal / Installation 55
Front Cab Removal / Installation 59
Front Cover Removal / Installation54
Front Drive Axle Installation 74
Front Drive Axle Removal 72
Front Gearcase – Back Lash Pad Adjustment718
Front Gearcase Coil Resistance714, 723
Front Gearcase Lubrication 212
Front Gearcase, Active Descent Control Exploded View 721
Front Gearcase, Diagnoses719
Front Gearcase, Disassembly / Inspection713
Front Gearcase, Exploded View 711
Front Gearcase, Installation 720
Front Gearcase, Operation711
Front Gearcase, Reassembly 729
Front Gearcase, Reassembly / Inspection717
Front Gearcase, Removal 712
Front Hub, Assembly 76
Front Hub, Disassembly76
Front Storage Installation 58
Front Storage Removal56
Fuel Filter 416
Fuel Filter, Replacement 217, 446
Fuel Gauge Sender, Installation 447
Fuel Gauge Sender, Removal 446
Fuel Injection, Component Locations 49
Fuel Injection, Exploded View48
Fuel Injection, Service Notes 47
Fuel Injection, Special Tools 45
Fuel Injector 416
Fuel Level Test443
Fuel Pressure Regulator 415
Fuel Pump / Tank Assembly 413
Fuel Pump, Testing 445
Fuel Sender Test 1042
Fuel System Special Tools432
Fuel System, EFI Circuit Diagrams 426
Fuel System, Inspection 216
Fuel Tank Location 410
Fuel Tank/Fuel Delivery System 444
G
Gear Position Indicator Switch Test1026
Gearcase, ADC Hydraulic Fluid Change 214
Gearcase, Front Capacity and Fluid Type 72
Glossary of Terms115
IX3
IX H
Handlebar Block Installation Procedure 516
Headlamp Switch Test 1039
Headlight Housing Replacement1037
Headlight Pod Exploded View515
High Beam Bulb Replacement 1036
High Beam Headlight Adjustment 1038
Hydraulic Brake System Operation Overview 96
I
Ignition System 1028
Ignition System Troubleshooting1031
Instrument Cluster (Speedometer) Overview1013
Instrument Cluster Diagnostic Mode1014
Instrument Cluster Overview1013
Instrument Cluster, Setting New Service Interval 1016
K
Keys, Replacement 13
L
Low Beam Headlight Adjustment 1039
Low Maintenance Battery Charging 1061
Low Maintenance Battery Info 1061
Lower Headlamp Housing Removal1039
Lower Headlamp Removal 1038
Lubricants/Fluids, Polaris Brand Part Numbers29
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
210
M
Maintenance Chart 24
Maintenance Schedule238
Maintenance, General Information 23
MAP Sensor 418
Mikuni Jet Part Numbers 432
Misc Tables 112
Model 12
Model Number Information12
N
Needle and Seat, Leakage Test442
O
Oil Flow Chart312
Oil Flow, Overview 311
Oil Pressure Test, Engine 311
Oil Pump Priming Procedure 311
Oil Pump Shaft Endplay Adjustment 339
Oil Pump, Removal and Inspection 333
P
Paint Codes 13
Passenger Seat, Operation529
PDM, 450 and 500 EFI Overview105
PDM, 450 Connector Pin Table 1011
PDM, X2/EFI Connector Pin Table 107
Pilot System 436
Piston Identification36
Piston Removal 328
Piston Ring Installation 330, 343
Plastic Inserts 53
Power Distribution Module 105
Pre-ride Checklist210
Propshaft, Removal77
Publication Numbers 13
PVT Assembly 611
PVT Disassembly610
PVT Drive Clutch Operation 66
PVT Drive Clutch Shift Weights 69
PVT Drive Clutch Specifications 68
PVT Driven Clutch Operation 66
PVT Drying 610
PVT Ducting 63
PVT Maintenance / Inspection67
PVT Operation66
PVT Overheating Chart 636
PVT Special Tools62
PVT Torque Specs62
PVT Troubleshooting Chart 637
PVT, Button to Tower Clearance 617, 630
PVT, Clutch Alignment 614
PVT, Clutch Offset 614
PVT, Drive Belt Installation 613
PVT, Drive Belt Removal/Inspection612
PVT, Drive Clutch Disassembly615, 628
PVT, Drive Clutch Exploded View63
PVT, Drive Clutch Reassembly620, 632
PVT, Drive Clutch Spider Removal615, 629
PVT, Driven Clutch Bushing Service624
PVT, Driven Clutch Disassembly622
PVT, Driven Clutch Reassembly625
PVT, EBS Clutch Operation 67
PVT, EBS Drive Clutch Bushing Service 618, 631
PVT, EBS Drive Clutch Cover Bushing Remove/Install 619,
632
PVT, Moveable Sheave Inspection 618, 631
R
Radiator Cap Pressure Test37
Radiator Screen Removal511
Rear Cab Removal / Installation 510
Rear Master Cylinder, Exploded View 926
Rear Rack Removal / Installation 58
Rear Storage Removal / Installation 511
Rear Suspension Assembly 522, 523
Recoil Housing, Draining / Inspection 222
Recoil, Reassembly 352
Recoil, Removal 351
S
Shift Linkage Inspection 214
Side Panel Removal 54
Solenoid, Differential 1036
Spark Plug, Inspection / Replacement218
Special Tools, Body & Steering 52
IX4
Special Tools, EFI 45
Special Tools, Engine 33
Special Tools, Final Drive 72
Special Tools, Speed Sensor1042
Specificaiton, Stator Plate Bolt Torque 349
Specification, Brake Disc Service Limit 925
Specification, Brake Disc Thickness 925
Specification, Brake Pad Thickness 919
Specification, Cam Chain Stretch332
Specification, Cam Chain Tensioner Spring 315
Specification, Camshaft Lobe Height318
Specification, Crankcase Bolt Torque341
Specification, Crankshaft Slotted Nut Torque 343
Specification, Cylinder Compression217
Specification, Cylinder Head Torque Procedure 345
Specification, Cylinder Head Warp 321
Specification, Cylinder Taper329
Specification, Cylinder Warp328
Specification, Differential Solenoid Resistance 1036, 1042
Specification, Differential Solenoid Torque 1036, 1042
Specification, Drill and Tap Sizes113
Specification, Flywheel Nut Torque 349
Specification, Fuel Pump Pressure 413
Specification, Oil and Filter 223
Specification, Oil Pip Bolt Torque 350
Specification, Oil Pump Bolt Torque334
Specification, Oil Pump Shaft Endplay 339
Specification, One Way Valve Spring Length 332
Specification, Piston to Cylinder Clearance 329
Specification, PVT Center-to-Center Distance 613
Specification, PVT Component Torque Table62
Specification, PVT Drive Belt Width613
Specification, Rocker Arm and Shaft315
Specification, Rocker Shaft Bolt Torque350
Specification, Spark Plug Gap 218
Specification, Speed Sensor Bolt Torque 1042
Specification, Tensioner Blade Bolt Torque 343
Specification, Transmission Silent Chain Length817
Specification, Valve Clearance 226, 326
Specification, Valve Guide Height 323
Specification, Valve Stem and Guide322
Specifications, Body and Steering Torque Values52
Specifications, Brake Component Service Limits 92
Specifications, Brake Component Torque Values92
Specifications, Engine Fastener Torque 33
Specifications, Engine Service Data 34
Specifications, Final Drive Torque Values72
Specifications, Front Gearcase Lubrication Type/Capacity 72
Specifications, Piston329
Specifications, Power Distribution Module1010
Specifications, Standard Torque Values 112
Specifications, Vehicle 16, 18, 110
Speed Sensor1042
Speedometer Installation1018
Speedometer Removal 1018
Speedometer Troubleshooting Tests1019
Starter Armature Testing1047
Starter Assembly Exploded View 1048
Starter Brush Inspection / Replacement 1046
Starter Drive 1049
Starter Drive Removal331
Starter Lockout, Troubleshooting 1044
Starter Motor Dissassembly / Replacement 1046
Starter Reassembly / Installation1048
Starter System Flow Chart 1050
Steering A-Arm Exploded View 517
Steering Lock, Exploded View 114
Steering Post Assembly 520
Steering Post Removal520
Steering Torque Values52
Steering, Inspection 226
Storage Compartment, Latch Operation 233
Strut Assembly521
Strut Cartridge Replacement, Front 520
Suspension, Inspection231
T
Thermostat Installation 350
Throttle Cable215
Throttle Position Sensor 420
Throttle Position Sensor Initialization421
Throttle Position Sensor Replacement421
Throttle, Linkage Inspection 215
Tie Rod, Inspection 227
Trail Boss Emissions System 115
Transmission 81
Transmission ID Information 12
Transmission Mounts, Exploded View82
Transmission, Disassembly89
Transmission, Exploded View 87
Transmission, Fluid Check / Change 213
Transmission, Install 85
Transmission, Output Shaft Backlash Procedure 815
Transmission, Reassembly814
Transmission, Removal83
Transmission, Special Tools 83
Troubleshooting Diagrams, Elelctrical 1052
Troubleshooting, EFI Circuit Diagrams 426
Troubleshooting, Engine 353
U
U-joint, Disassembly and Assembly 77
V
Valve Clearance Adjustment 226, 326
Valve Seat Reconditioning323
Vehicle Identification Number (VIN) 12
Voltage Drop Test 1044
W
Warn Winch Operation 234
Water Pump Seal, Installation341
Wheel Alignment 227
IX5
IX Wheels, Removal 232
Wheels, Tire Pressure 232
Wheels, Torque Table 232
Wire Diagram, Winch Basic 1051
Wire Diagrams, Electrical 1052
Work Light Switch 1040
X
X2, Seat Disassembly 530
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