Polaris Sportsman 300 / 400 H.O Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Sportsman 300 / 400 H.O has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2009 SPORTSMAN 300
MODEL NUMBER: A09LH27AX, A09LH27AZ
ENGINE MODEL: ES300PFE012

MODEL: 2009 SPORTSMAN 400 H.O.
MODEL NUMBER: A09LH46AQ, A09LH46AX, A09LH46AZ
ENGINE MODEL: EH460PLE020

TABLE OF CONTENTS :

CH 01-GENERAL INFORMATION
CH 02-MAINTENANCE
CH 03-ENGINE
CH 04-FUEL SYSTEM
CH 05-BODY / STEERING / SUSPENSION
CH 06-CVT / TRANSMISSION
CH 07-FINAL DRIVE
CH 08-BRAKES
CH 09-ELECTRICAL
WIRE DIAGRAM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921820
Total Pages : 292

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9921820_CH 01-GENERAL INFORMATION
TABLE OF CONTENTS
VEHICLE IDENTIFICATION
Model Identification
Engine Designation Number
Vehicle Identification Number (VIN)
Vehicle and Engine Serial Number Locations
SPECIFICATIONS
MODEL: 2009 SPORTSMAN 300
MODEL: 2009 SPORTSMAN 400 H.O.
MODEL: 2009 SPORTSMAN 300
MODEL: 2009 SPORTSMAN 400 H.O.
VEHICLE INFORMATION
Publication Numbers
Replacement Keys
Special Tools
MISC. SPECIFICATIONS AND CHARTS
Standard Torque Specifications
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Conversion Table
Glossary Of Terms
9921820_CH 02-MAINTENANCE
TABLE OF CONTENTS
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Break-In Period
Maintenance Chart Key
Maintenance Intervals
Grease Lubrication Points
Maintenance quick reference
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants,Maintenance and Service Products
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-ride / Daily Inspection
Frame, Nuts, Bolts, Fasteners
Controls
Handlebar Component Locations
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Fuel Filter
Vent Lines
Throttle Operation
Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment
Choke (Enricher) Adjustment
Fuel Valve
Carburetor Draining
Pilot Screw Location
Pilot Screw and Idle Speed Adjustment
Main Air Filter Cleaning
Air Filter / Pre-Filter Service (300)
Air Filter / Pre-Filter Service (400 H.O.)
Air Box Sediment Tube
ENGINE
Engine Oil Level (Sportsman 300)
Engine Oil and Filter Change (Sportsman 300)
Engine Oil Level (Sportsman 400 H.O.)
Engine Oil and Filter Change (Sportsman 400 H.O.)
Oil Pump Priming Procedure (Sportsman 400 H.O.)
Engine Breather Hose
Engine Breather Filter (Sportsman 300)
Engine Breather Filter (Sportsman 400 H.O.)
Valve Clearance (Sportsman 300)
Valve Clearance (Sportsman 400 H.O.)
Recoil Housing
Compression and Leakdown Tests
Exhaust Silencer Cleaning
Engine Mount Fastener Torque
TRANSMISSION / FRONT GEARCASE
Transmission Lubrication
Front Gearcase Lubrication
COOLING SYSTEM (400 H.O.)
Cooling System Overview
Coolant Level Inspection
Coolant Strength / Type
Cooling System Pressure Test
Cooling System Hoses
Radiator
Coolant Drain / Radiator Removal
CVT / FINAL DRIVE / WHEEL AND TIRE
CVT Drying
Drive Shaft Boot Inspection
Wheel and Hub Torque Table
Wheel Removal
Wheel Installation
Tire Pressure
Tire Inspection
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Removal (Sportsman 300)
Battery Installation (Sportsman 300)
Battery Removal (Sportsman 400 H.O.)
Battery Installation (Sportsman 400 H.O.)
Spark Plug Service
STEERING AND SUSPENSION
Steering Inspection
Tie Rod End / Steering Inspection
Camber and Caster
Toe Alignment
Toe Alignment Adjustment
Suspension Inspection
Suspension Spring Preload Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad Inspection
Hose / Fitting Inspection
Brake Pedal Freeplay
9921820_CH 03-ENGINE
TABLE OF CONTENTS
300 ENGINE
TOOLS
Special Tools
TORQUE SPECIFICATIONS
Engine Torque Specifications
Torque Pattern (Cylinder Head)
GENERAL ENGINE SERVICE
Engine Exploded View
Engine Service Data
Engine Service Data
Oil Flow Diagram
Piston Identification
Piston Ring Identification
Accessible Components
ENGINE SERVICE
Engine Removal
Engine Lubrication
Oil Flow / Pressure Test
Engine Breather / Oil separator
Cam Chain Tensioner Removal
Cam Chain Tensioner Inspection
Rocker Arm / Rocker Arm Shaft Disassembly and Inspection
Camshaft Removal
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Warp Inspection
Combustion Chamber Inspection
Cylinder Head Disassembly
Valve Inspection
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Engine Bottom End Disassembly
Cam Chain Guide And Tensioner Blade
Piston Removal
Cylinder Inspection
Cylinder Hone Selection / Honing Procedure
Honing To Deglaze
Piston Inspection
Piston Ring Installed Gap
Flywheel Removal / Inspection
Starter Drive Removal / Inspection
Cam Chain Drive Sprocket Removal / Inspection
Oil Pump Inspection / Removal
Starting Clutch and Engine Braking Clutch Removal / Inspection
Starting Clutch Assembly
Starting Clutch Exploded View
Crankcase Disassembly
Crankcase Separation
Crankshaft Removal
Crankshaft / Cam Chain / Sprocket Inspection
Crankcase Oil Passages & Pressure Relief Valve
Camshaft Chain
Balance Shaft Bearing Inspection
Crankcase Oil Pickup Strainer Inspection
Bearing / Seal Installation
End Play Inspection / Adjustment
Crankshaft End Play Adjustment
Balancer Shaft End Play Adjustment
Crankcase Reassembly
Cam Chain, Oil Pump, & Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head and Camshaft Installation
Camshaft Installation & Timing
Cam Chain Tensioner Installation
Rocker Arm Installation
Starter Drive Assembly
Engine Installation Notes
TROUBLESHOOTING
Spark Plug Fouling troubleshooting
Engine Troubleshooting
400 H.O. ENGINE
SPECIAL TOOLS
SPECIFICATIONS
Torque Specifications
Engine Service Data
Engine Service Data
Engine Fastener Torque Patterns
GENERAL ENGINE SERVICE
Accessible Components
Engine Removal
Crankshaft Straightening
Engine Lubrication – EH460PLE020
Oil Pressure Test – EH460PLE020
Oil Flow – EH460PLE020
EH460PLE020 Oil Flow Diagram
EH460PLE020 Engine Exploded View
COOLING SYSTEM
Cooling System Specifications
Cooling System Layout and Testing
ENGINE DISASSEMBLY
Cam Chain Tensioner / Rocker Arm / Camshaft Removal
Cam Chain Tensioner Inspection
Rocker Arm / Shaft Inspection
Camshaft Removal
Automatic Compression Release Removal / Inspection
Automatic Compression Release Installation
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Exploded View, EH460PLE020
Cylinder Head Inspection
Cylinder Head Warpage
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Clearance Adjustment
Cylinder / Piston Removal and Inspection
Piston Removal
Cylinder Inspection
Cylinder Hone Selection / Honing Procedure
Honing to Oversize
Cleaning the Cylinder After Honing
Piston-to-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Starting Clutch Removal / Inspection
Starting Clutch Assembly
Starting Clutch Exploded View
Crankcase Disassembly
Starter Drive Removal / Inspection
Flywheel and Stator Removal / Inspection
Cam Chain / Tensioner Blade
One Way Valve
Crankcase Separation
Oil Pump Removal / Inspection
Oil Pump Assembly
Counter Balancer Shaft Removal / Inspection
Crankshaft Removal / Inspection
Crankcase Bearing Inspection
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
Crankcase Inspection
Bearing Installation
End Play Inspection / Adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
ENGINE REASSEMBLY
Pump Shaft Oil Seal Installation
Crankshaft / Counter Balance / Oil Pump Installation
Crankcase Assembly
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal (Engine Installed)
One Way Valve Installation
Cam Chain Drive Sprocket Installation
Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head Installation
Cam Chain / Camshaft Installation
Camshaft Timing
Camshaft Timing Illustration
Cam Chain Tensioner Installation
Stator, Flywheel and Starter Drive Installation
Rocker Shaft / Rocker Arm Assembly Installation
Thermostat Installation
Oil Pipes
Engine Installation Notes
Oil Pump Priming Procedure
TROUBLESHOOTING
Engine
Spark Plug Fouling
Cooling Troubleshooting
9921820_CH 04-FUEL SYSTEM
TABLE OF CONTENTS
CARBURETION INFORMATION
Special Tools
Carburetor Jetting
Mikuni Optional Jet Part Numbers
CV CARBURETION SYSTEM
Carburetor Venting Exploded View
Carburetor Venting
BST 34 Carburetor Exploded View (Upper Components)
BST 34 Carburetor Exploded View (Lower Components)
Carburetor Function
Mikuni CV Carb Operation
Starter System (Choke or Enrichment)
Pilot (Idle and Slow) System
Main System
Float System
Pilot Screw
Air/Fuel Mixture Ratio
Jet Needle
Needle Jet
Throttle Opening vs. Fuel Flow
CARBURETOR SERVICE – MIKUNI CV
Carburetor Disassembly
Carburetor Cleaning
Carburetor Inspection
Carburetor Assembly
Float Height Adjustment
Needle and Seat Leakage Test
Fuel Level test
Troubleshooting
FUEL TANK / FUEL DELIVERY SYSTEM
Fuel Tank / Fuel Delivery System
9921820_CH 05-BODY / STEERING / SUSPENSION
TABLE OF CONTENTS
TORQUE SPECIFICATIONS
PLASTIC RETAINER INSERTS
Removal / Installation
BODY ASSEMBLY
Exploded View
SEAT / SIDE PANEL / TANK COVER
Removal / Installation
FRONT BUMPER / CAB / FOOTWELL
Front Bumper Removal / Installation
Front Cab Removal
Front Cab Installation
Footwell Removal / Installation
REAR RACK / REAR CAB
Rear Rack Removal / Installation
Rear Cab Removal / Installation
INSTRUMENT POD
Pod / Key Switch / Choke / Instrument Cluster Removal / Installation
STEERING
Steering Post Removal
Steering Post Installation
Handlebar Block Installation Procedure
Tie Rod / Tie Rod End Replacement
FRONT SUSPENSION / A-ARM
Exploded View
A-arm Removal
Ball Joint Replacement
A-arm Installation
FRONT STRUT
Exploded View
Front Strut Removal
Front Strut Installation
REAR CONTROL ARMS
Exploded View
Control Arm Removal / Installation
REAR TORSION BAR
Exploded View
REAR SHOCKS / SPRINGS
Exploded View
Shock Removal / Installation
Shock / Spring Replacement
DECAL REPLACEMENT
9921820_CH 06-CVT / TRANSMISSION
TABLE OF CONTENTS
CVT SYSTEM
Torque Specifications
Clutch Roller Weights
Special Tools
CVT Operation Overview
Starting Clutch Operation
Drive Clutch Operation
Driven Clutch Operation
Engine Braking Clutch
CVT Maintenance / Inspection
CVT Drying
CVT Overheating / Diagnosis
CVT System Disassembly
Drive Belt Inspection
Drive Clutch Service
Driven Clutch Service
Starting Clutch Exploded View (Sportsman 300)
Starting Clutch Exploded View (Sportsman 400 H.O.)
TRANSMISSION
Torque Specifications
Shift Linkage Inspection
Gear Selector Removal
Transmission Removal
Transmission Disassembly
Transmission Reassembly
Transmission Installation
Transmission Exploded View
9921820_CH 07-FINAL DRIVE
TABLE OF CONTENTS
GENERAL SPECIFICATIONS
Torque Specifications
Special Tools
FRONT BEARING CARRIER
Bearing Carrier Removal
Bearing Removal
Bearing Installation
Bearing Carrier Installation
PROPSHAFT SERVICE
Removal
Installation
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE CENTRALIZED HILLIARD
All Wheel Drive Operation
Centralized Hilliard Exploded View
AWD Diagnosis
Gearcase Removal
Disassembly
Gearcase Reassembly
Installation
REAR BEARING CARRIER
Bearing Carrier Inspection
Bearing Carrier Removal
Bearing Removal
Bearing Installation
Bearing Carrier Installation
DRIVE SHAFT SERVICE
Front Drive Shaft Removal
Rear Drive Shaft Removal
Drive Shaft / CV Joint Handling Tips
Outer CV Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Exploded View
Front Drive Shaft Installation
Rear Drive Shaft Installation
9921820_CH 08-BRAKES
TABLE OF CONTENTS
SPECIFICATIONS
General Brake Specifications
General Torque Specifications
Special Tools
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
BRAKE CALIPER
Exploded View
HAND MASTER CYLINDER
Exploded View
BRAKE BLEEDING
Fluid Replacement
Bleeding Procedure
HAND MASTER CYLINDER
Removal
Disassembly
Installation
FOOT MASTER CYLINDER
Operation Overview
FOOT BRAKE PEDAL
Foot Pedal Removal / Installation
Foot Master Cylinder Removal / Installation
BRAKE PADS
Pad Removal
Pad Installation
Brake Burnishing Procedure
CALIPER SERVICE
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Reassembly
Caliper Installation
BRAKE DISC SERVICE
Disc Inspection
Disc Removal / Replacement
TROUBLESHOOTING
Brake Squeal
9921820_CH 09-ELECTRICAL
TABLE OF CONTENTS
GENERAL INFORMATION
Special Tools
Electrical Service Notes
Component Locations
INSTRUMENT CLUSTER
Display Functions
AWD Control System
Instrument Cluster Overview
Rider Information Display
Display Modes
Instrument Cluster Removal
ALL WHEEL DRIVE COIL
Operation Overview
Diagnosing System Failures
SPEED SENSOR
Vehicle Speed Sensor
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
Electronic Throttle Control (ETC) Switch
GEAR SELECTOR SWITCH
Switch Test
ETC / REVERSE RPM CONTROL
ETC / Reverse RPM Control System
FUSIBLE LINK / FUSES / CIRCUIT BREAKERS
Fusible Link
Fuse and Circuit Breaker Function
FAN MOTOR / COOLING SYSTEM THERMAL SWITCHES (400 H.O.)
Cooling System Electrical Break-Out Diagram
Fan Motor Circuit Operation
Fan Motor Circuit Bypass Test
Fan Switch (Thermal Switch) Replacement
Engine Temperature Switch Operation
Engine Temperature Switch Replacement
IGNITION SYSTEM
DC/CDI Ignition System Diagram
RPM Limit Modes
Ignition System Troubleshooting
Ignition Coil Testing (Sportsman 300)
Ignition Coil Testing (Sportsman 400 H.O.)
Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter
Ignition Timing
Ignition System Testing
LIGHTS
Headlight Adjustment
Headlight Lamp Replacement
Tail / Brake Light Bulb Replacement
CHARGING SYSTEM
Charging System Diagram
Charging System Testing Flow Chart
Current Draw – Key Off
Charging System “Break Even” Test
Charging System Alternator Tests
BATTERY SERVICE
Battery Identification
CONVENTIONAL BATTERY (SPORTSMAN 300)
Battery Activation
Battery Inspection
Battery Removal / Installation
Conventional Battery Testing
OCV – Open Circuit Voltage Test
Specific Gravity Test
Load Test
Battery Off Season Storage
Charging Procedure (Conventional)
LOW MAINTENANCE BATTERY (SPORTSMAN 400 H.O.)
General Battery Information
Battery Removal / Installation
Battery Testing
OCV – Open Circuit Voltage Test
Load Test
Battery Off Season Storage
Charging Procedure (Low Maintenance)
STARTER SYSTEM
Starter / Starter Lockout System Diagram
Troubleshooting
Voltage Drop Testing
Starter Motor Removal / Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly / Installation
Starter Drive
Starter Solenoid Bench Test
Starter Solenoid Operation
Starter Motor Exploded View
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter motor fails to turn over the engine.
9921820_WIRE DIAGRAM
Sportsman 300
Sportsman 400 H.O.

 

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Polaris Sportsman 300 / 400 H.O Repair Service Manual 2009.pdf

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