DOWNLOAD Polaris Sportsman Repair Manual (1993-2013 Model)

Polaris ATV Repair Manual Service Manual

A Polaris Sportsman all-terrine-vehicle (ATV) or utility vehicle (UTV) repair manual is a book of repair instructions designated to teaching you how to overhaul, fix or maintain the 4-wheeler or 6-wheeler back to factory specifications.

A Polaris Sportsman off-road vehicle repair manual is also termed a service manual, workshop manual or shop manual. It’s composed of several manuals, including a maintenance manual, troubleshooting manual and a step-by-step repair guide.

The repair sections describe in detail the specific repairs that are approved for a particular Polaris Sportsman ATV or UTV model. Here is a small example of chapters and sub-chapters found in a Polaris all-terrine-vehicle repair manual:

General Information

  • Model Identification
  • Serial Number Locations
  • Replacement Keys
  • Standard Troque Specifications
  • Component Specifications
  • Tap Drill Charts
  • Decimal Equivalent Chart
  • Unit of Measure Conversion Table
  • Glossary of terms

Engine And Transmission

  • Torque Specifications
  • Service Data
  • SpecialTools
  • Torque Patterns
  • Piston Identification / Compression Test
  • Cooling System Pressure Test
  • Cooling System Specifications
  • Engine Removal
  • Engine Installation Notes
  • Engine Lubrication
  • Crankshaft Inspection
  • Oil Pump Priming Procedure
  • Lubrication/Oil Flow
  • Engine Oil Flow Diagram
  • Engine Exploded Views
  • Engine Top End Service
  • Camshaft
  • Cylinder Head
  • Engine Bottom End Service
  • Transmission
  • Crankshaft Runout Inspection
  • Crankcase & Bearings
  • Water Pump Shaft/Seal Service
  • Engine Assembly
  • Crankcase
  • Piston/Cylinder
  • Cam Timing
  • Cam Timing Diagram
  • Cylinder Honing
  • Valve Seat Service
  • Troubleshooting
  • Spark Plug Fouling Checklist
  • Cooling Troubleshooting Checklist

Body And Steering

  • Torque Specifications and Special Tools
  • Body Assembly, Exploded View
  • Steering Assembly, ExplodedView
  • Front Hub Removal
  • Front Hub Assembly/Installation
  • Steering Knuckle Removal/Installation
  • Ball Joint Removal/Installation
  • Front Hub Exploded View
  • A-Arm Replacement
  • Concentric Swing Arm Removal
  • Rear Axle Removal/Disassembly
  • Rear Axle Removal/Disassembly
  • Steering Post Assembly/Decal Replacement
  • Front Shock Service
  • Rear Shock Service

Brakes

  • Specifications/Torques
  • SpecialTools
  • Brake System Service Notes
  • Brake Noise Troubleshooting
  • Hydraulic Brake System Operation
  • Fluid Replacement/Bleeding Procedure
  • Master Cylinder Removal
  • Master Cylinder Installation
  • Front Pad Removal/Install
  • Front Pad Assembly
  • Front Disc Inspection
  • Front Disc Removal/Replacement
  • Front Caliper Removal/Install
  • Rear Pad Removal
  • Rear Pad Installation
  • Rear Caliper Removal/Inspection
  • Front/Rear Caliper Disassembly
  • Front/Rear Caliper Assembly
  • Rear Brake Disc Inspection
  • Troubleshooting
  • Caliper Exploded View
  • Front Brake System
  • Rear Brake System

Troubleshooting

  • Fuel System Troubleshooting
  • Troubleshooting Diagrams
  • Starter System Troubleshooting
  • Engine Turns But Fails to Start
  • Engine Does Not Turn Over
  • Engine Idles But Will Not Rev UP
  • Engine Has Low Power
  • Piston Failure
  • Excessive Smoke And Carbon Buildup
  • Low Compression
  • Backfiring
  • Spark Plug Fouling
  • Cooling System
  • Temperature Too Low
  • Leak at Water Pump Weep Hole
  • Transmission Troubleshooting
  • Brake System Troubleshooting

Maintenance

  • Periodic maintenance chart
  • Pre-ride inspection
  • Periodic Maintenance Chart
  • Pre-Ride Inspection  
  • Lubricant and Maintenance Product Numbers
  • SpecialTools  
  • Lubrication Charts
  • Clutch Free-play Adjustment  
  • Throttle Inspection  
  • Carburetor Adjustments
  • Throttle Adjustment  
  • Fuel System  
  • Compression Test
  • Spark Plug Maintenance
  • Battery Maintenance  
  • Electrical  
  • Coolant System Maintenance
  • Radiator Screen Removal
  • Air Filter Service
  • Air Box Sediment Tube Service
  • Crankcase Breather Filter
  • OilChange/Filter  
  • Steering and Toe Alignment  
  • Exhaust System Maintenance  
  • Brake System Service  
  • Suspension Adjustment  
  • Controls / Handlebar Adjustment
  • Wheel Removal/Installation
  • Tire Inspection

Fuel System (Carb & EFI)

  • Exploded View Carburetor
  • Fuel Tank Asm. Exploded View
  • Fuel Flow Diagram
  • Special Tool & Jetting Guidelines
  • Carburetor Jetting
  • Main Jet / Pilot Jet Part Numbers
  • CV Carburetor System Function (4 Cycle)
  • CV Carburetor Vent System (4 Cycle)
  • CV Carburetor Operation
  • Disassembly Notes, CV Carburetor
  • Cleaning, CV Carburetor
  • Inspection, CV Carburetor
  • Assembly, CV Carburetor
  • FloatAdjustment, CV Carburetor
  • Needle & Seat Leakage Test
  • Fuel Level
  • Fuel Pump Service
  • Troubleshooting
  • Electronic Fuel Injection Exploded View
  • EFI System
  • Fuel Lines
  • Fuel Pump Assembly
  • Fuel Pressure Regulator
  • Fuel Filters
  • Fuel Injector
  • Manifold Air Pressure Sensor (MAP)
  • Crankshaft Position Sensor (CPS)
  • Intake Air Temperature Sensor (IAT)
  • Idle Air Control (IAC)
  • Throttle Position Sensor (TPS)
  • Electronic Control Module (ECM)
Engine Temperature Sensor
  • EFI Diagnostics Using ‘Blink Codes’

Electrical

  • Special Tools/Service Notes
  • Timing Check Procedure
  • Electrical Switch Testing
  • FanMotorCurrentDrawTest
  • Electronic Throttle Circuit System Operation
  • Ignition System Troubleshooting
  • CDI Output Tests/Stator Output Tests
  • Flywheel Identification
  • Ignition System
  • Alternator, Exploded
  • Ignition System Testing
  • Charging System Testing
  • Battery Activation/Service
  • Head Light/Brake Light Lamp Service
  • BrakeLight/TailLightService
  • Brake Lamp Service
  • Clutch/TetherSwitch
  • Starter Motor Service
  • StarterDrive
  • Starter System Testing Flow Chart
  • Wiring Diagrams

Repair sections begin with vehicle specifications, such as competent specs, torque specifications and other data (special tools or solvents required, etc.). Subsequent information contains serving or repair information, such as part removal, disassembly, cleaning, assembly, installation and testing.

All repair chapters also contain diagrams, pictures and illustrations to help guide you through the repair procedures being discussed. Simply put, a Polaris repair manual covers every aspect of repair—from basic maintenance to complete engine overhaul.

Polaris Sportsman repair manuals can be downloaded to most electronic devices, such as a computer, tablet or smart-phone. Although it’s recommended to download a repair manual to a computer or tablet instead of a phone. Polaris repair manuals can be downloaded instantly. That means you can start fixing your Polaris off-road-vehicle now.

Polaris owners are often skeptical about downloading a repair manual. It’s often believed that you will need to buy software to download and view the manual. However, this is not the case. Polaris repair manuals are in PDF (portable document format) and require no additional software to view it. Modern electronic devices are factory preinstalled with the needed software to view the manual.

A download repair manual appears just like any book you’d buy in a store. It contains a cover page, table of contents, main chapters and index page. The digital book is more user friendly than a original paperback version. Digital manuals contain clickable chapters that allow you to locate the information with the click of a mouse.

3 Comments

  1. Do you have a list of all Polaris Sportsman repair manuals? How quick is the download and will it work on a MAC computer?

    • All download repair manuals can be downloaded in under a minute. These manuals can be downloaded, viewed and saved on any operating system (MAC Windows, whatever). We have repair manuals for all models listed:

      1993 Polaris Sportsman
      1994 Polaris Sportsman 4X4
      1995 Polaris Sportsman 4X4
      1996 Polaris Sportsman 500
      1996 Polaris Sportsman 4X4 400L
      1997 Polaris Sportsman 400 4X4 400 L
      1997 Polaris Sportsman 500
      1998 Polaris Sportsman 500
      1999 Polaris Sportsman 335 4X4
      1999 Polaris Sportsman 500 4X4
      2000 Polaris Sportsman 335 4X4
      2000 Polaris Sportsman 500 4X4
      2000 Polaris Sportsman 500 6X6
      2000 Polaris Sportsman 500 RSE 4X4
      2001 Polaris Sportsman 90
      2002 Polaris Sportsman 700
      2003 Polaris Sportsman 600
      2003 Polaris Sportsman 700
      2003 Polaris Sportsman 90
      2004 Polaris Sportsman Early Sportsman 600
      2004 Polaris Sportsman Early Sportsman 700
      2004 Polaris Sportsman Late Sportsman 600
      2004 Polaris Sportsman Late Sportsman 700
      2004 Polaris Sportsman 90
      2005 Polaris Sportsman 400
      2005 Polaris Sportsman 500
      2005 Polaris Sportsman 700 EFI
      2005 Polaris Sportsman 800 EFI
      2007 Polaris Sportsman 700 EFI
      2007 Polaris Sportsman 800 EFI
      2007 Polaris Sportsman X2 800 EFI
      2007 Polaris Sportsman 450 EFI
      2007 Polaris Sportsman 500 EFI
      2007 Polaris Sportsman 500 X3 EFI
      2008 Polaris Sportsman 500
      2008 Polaris Sportsman 500 EFI
      2008 Polaris Sportsman X-2 500 EFI
      2008 Polaris Sportsman 800 EFI
      2008 Polaris Sportsman X2 700 EFI
      2008 Polaris Sportsman Touring 800 EFI
      2009 Polaris Sportsman 90
      2009 Polaris Sportsman 300
      2009 Polaris Sportsman 400 H.O.
      2009 Polaris Sportsman 500 H.O.
      2009 Polaris Sportsman 500 EFI
      2009 Polaris Sportsman X2 500 EFI
      2009 Polaris Sportsman Touring 500 EFI
      2009 Polaris Sportsman 800 6X6 EFI
      2009 Polaris Sportsman 800 EFI
      2009 Polaris Sportsman X2 800 EFI
      2009 Polaris Sportsman Touring 800 EFI
      2009 Polaris Sportsman 90
      2009 Polaris Sportsman XP 550
      2009 Polaris Sportsman XP550 EPS
      2009 Polaris Sportsman XP 850
      2009 Polaris Sportsman XP 850 EPS
      2011 Polaris Sportsman 850 XP EPS Repair Manual
      2011 Polaris Sportsman XP 850
      2011 Polaris Sportsman XP 850 EPS / and International
      2011 Polaris Sportsman XP 850 / XP 850 EPS / and International
      2011 Polaris Sportsman X2 850
      2011 Polaris Sportsman Touring 850 / and International
      2011 Polaris Sportsman X2 850 / Touring 850 / and International
      2012 Polaris Sportsman 400 H.O.
      2012 Polaris Sportsman 500 H.O.
      2012 Polaris Sportsman Touring 500 HO
      2012 Polaris Sportsman Forest Tractor 500 EFI
      2014 Polaris Sportsman 570 EFI / EPS
      2014 Polaris Sportsman Forest 50 EFI / EPS
      2014 Polaris Sportsman Touring 570 EFI / International

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