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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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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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