Polaris Sportsman 300-400 (2009) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 300-400 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 300-400 (2009).

 
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
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
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
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
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
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
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
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
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
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.