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2012-2014 Polaris Sportsman 400 HD Service Manual
By
colin james, in Polaris ATV Forum
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Similar Topics
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By jwline
Friday evening went riding, rode for a good hour or so everything was fine. I went to take a short ride to the restroom (less than 100 yds away) and all of the sudden everything flickered and then just died out. Accompanying the problem I noticed the killswitch completely locked up. Once daylight hit took the killswitch apart to find it had shorted out and melted the plastic inside. Has anyone else had anything similar to this and if so what did you do to fix the situation? I have a new killswitch on the way to replace the obvious problem but was wondering could there be a bigger issue at hand. We tested with a voltage meter to make sure everything was still getting power from the battery and as far as we could tell it was.
Any advice/info would be GREATLY appreciated.
Thanks.
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By Jarheadgreasemonkey
Just picked up a '95 Magnum from a local auction for $300 as my first project ATV...
Engine looks like it's tagged as EPA compliant for '98.
Everything else looks factory, and generally in good shape.
I'll post updates here as I make some progress on it.
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By Zad
1994 Polaris 300 2x4 project won’t start. Seems like we have spark and have tried straight starting fluid in cylinder and still not getting a fire. Kind of has me stymied
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By GatorHunter
Clymer ATV Manual - Polaris ATVs
You can also find ATV Manuals on Amazon.
Here is my list, some I have had, some I got online
I have put all Manuals on my dedicated server, so the links won't go dead. Most the manuals listed below are on the server and there may be some on the server that's not on the list. Scroll to the bottom of this post to get the link.
If you need a Manual that's not on the list, leave a reply, I will try to locate it, if I can't, I'm sure another member would share if they have it.
If you have manuals that are not in the list and you would like to share them, leave a reply, with a link to your manuals and I will add them to my post so they are all in one spot.
Thank you, and enjoy
GH
1985 thru 1995 Polaris Service Manual
Below is the list of machines this Manual covers
1985 Scrambler
1985 Trail Boss
1986 Scrambler
1986 Trail Boss
1987 Trail Boss
1987 Trail Boss 4X4
1987 Cyclone
1988 Trail Boss 2X4
1988 Trail Boss 4X4
1988 Trail Boss 250 R/ES
1989 Trail Boss
1989 Trail Boss 2X4
1989 Trail Boss 4X4
1989 Big Boss 4X6
1990 Trail Blazer
1990 Trail Boss 250
1990 Trail Boss 2X4
1990 Trail Boss 2X4 350L
1990 Trail Boss 4X4
1990 Trail Boss 4X4 350L
1990 Big Boss 4X6
1991 Trail Blazer
1991 Trail Boss 250
1991 Trail Boss 2X4
1991 Trail Boss 2X4 350L
1991 Trail Boss 4X4
1991 Trail Boss 4X4 350L
1991 Big Boss 4X6
1991 Big Boss 6X6
1992 Trail Blazer
1992 Trail Boss 250
1992 Trail Boss 2X4
1992 Trail Boss 2X4 350L
1992 Trail Boss 4X4
1992 Trail Boss 4X4 350L
1992 Big Boss 4X6
1992 Big Boss 6X6
1993 250 2X4
1993 350 2X4
1993 250 4X4
1993 350 4X4
1993 250 6X6
1993 350 6X6
1993 Trail Boss
1993 Trail Blazer
1993 Sportsman
1994 300 2X4
1994 400 2X4
1994 300 4X4
1994 400 4X4
1994 300 6X6
1994 400 6X6
1994 Trail Boss 2W
1994 Trail Blazer 2W
1994 Sportsman 4X4
1994 Sport
1995 300 2X4
1995 400 2X4
1995 300 4X4
1995 400 6X6
1995 Trail Boss
1995 Trail Blazer
1995 Sportsman 4X4
1995 Sport
1995 Xplorer 4X4
1995 Scrambler
1995 Magnum 2x4
1995 Madnum 4X4
1996 thru 1998 Polaris Service Manual
Below is the list of machines this Manual covers
1996 Trail Blazer
1996 Trail Boss
1996 Xplorer 300
1996 Xpress 300
1996 Xplorer 400
1996 Xpress 400
1996 Sport
1996 Scrambler 4X4
1996 Sportsman 4X4
1996 Sportsman 500
1996 400 6X6
1996 Magnum 2X4
1996 Magnum 4X4
1996 Magnum 6X6
1997 Trail Blazer
1997 Trail Boss
1997 Xplorer 300
1997 Xpress 300
1997 Xplorer 400
1997 Xpress 400
1997 Xplorer 500
1997 Sport 400
1997 Scrambler 4X4
1997 Scrambler 500
1997 Sportsman 4X4
1997 Sportsman 500
1997 400 6X6
1997 Magnum 2X4
1997 Magnum 4X4
1997 Magnum 6X6
1998 Trail Blazer
1998 Trail Boss
1998 Xplorer 300
1998 Xpress 300
1998 Sport 400
1998 Scrambler 400
1998 Scrambler 500
1998 Xplorer 400
1998 Magnum 2X4
1998 Magnum 4X4
1998 Sportsman 500
1998 Big Boss 500 6X6
1996 thru 2003 Sportsman 400 and 500, Xplorer 500 4X4 Service Manual
Below is the list of machines this Manual covers
1996 Sportsman 400
1996 Sportsman 500
1996 Xplorer 500 4X4
1997 Sportsman 400
1997 Sportsman 500
1997 Xplorer 500 4X4
1998 Sportsman 400
1998 Sportsman 500
1998 Xplorer 500 4X4
1999 Sportsman 400
1999 Sportsman 500
1999 Xplorer 500 4X4
2000 Sportsman 400
2000 Sportsman 500
2000 Xplorer 500 4X4
2001 Sportsman 400
2001 Sportsman 500
2001 Xplorer 500 4X4
2002 Sportsman 400
2002 Sportsman 500
2002 Xplorer 500 4X4
2003 Sportsman 400
2003 Sportsman 500
2003 Xplorer 500 4X4
2001 Sportsman 90 Service Manual
2001 Scrambler 50 and 90 Service Manual
2001 Sportsman 500 DUSE Parts Manual rev.2
A01CH50AD
2001 Sportsman 500 HO Parts Manual rev.3
A01CH50AA
A01CH50AB
A01CH50AE
A01CH50AK
2001 Sportsman 500 DUSE HO Parts Manual rev.3
A01CH50AF
2001 Sportsman 500 RSE HO Parts Manual rev.3
A01CH50AJ
2001 Worker 500 Parts Manual rev.3
A01CH50EB
2002 Sportsman 6X6 Parts Manual rev. 1
A02CL50AA
2002 Big Boss 6X6 INTL Parts Manual rev.1
A02CL50DA
2002 Sportsman 500 HO Parts Manual rev.4
A02CH50AA
A02CH50AB
A02CH50AE
A02CH50AK
2002 Sportsman 500 RSE Parts Manual rev.4
A02CH50AC
2002 Sportsman 500 DUSE Parts Manual rev.4
A02CH50AD
2002 Sportsman X Parts Manual rev.4
A02CH50AJ
2002 Sportsman 500 HO Freedom Parts Manual rev.4
A02CH50AL
2002 Sportsman 500 PSE HO Parts Manual rev.4
A02CH50AM
2002 Sportsman 500 Parts Manual rev.4
A02CH50AN
2002 Desert Sportsman 500 Parts Manual rev.4
A02CH50FA
2002 Worker 500 Parts Manual rev.4
A02CH50AAEB
2002 Sportsman 700 Parts Manual rev.2
A02CH68AA
A02CH68AB
A02CH68AC
A02CH68CA
A02CH68CB
2002 Sportsman 700 Service Manual
2003 Sportsman 6X6 Owners Manual
2003 Sportsman 6X6 Parts Manual rev.1
A03CL50AA
2003 Sportsman 6X6 Service Manual
2003 Sportsman 400 and 500 HO Service Manual
2003 Sportsman 400 Parts Manual
A03CH42AA
A03CH42AB
A03CH42AC
2003 Sportsman 500 HO Parts Manual
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
2003 Sportsman 600 and 700 Owners Manual
2003 Sportsman 600 and 700 Service Manual
2003 Sportsman 700 Parts Manual rev.4
2003 Predator Parts Manual rev. 1
A03GJ50AA
A03GJ50AB
2003 Trail Boss 330 Service Manual
2004 Sportsman 6X6 Parts Manual
A04CL50AA
2004 Sportsman 6X6 Owners Manual
2004 Sportsman 6X6 Service Manual
2004 Sportsman 400,500,600 and 700 Owners manual
2004 Sportsman 400 Parts Manual rev.1
A04CH42AA
A04CH42AE
A04CH42AG
2004 Sportsman 400 Parts Manual rev.1
A04CH42AQ
A04CH42AT
A04CH42AV
A04CH42AS
A04CH42AR
2004 Sportsman 500 Parts Manual rev.1
A04CH50AA
A04CH50AC
A04CH50AE
A04CH50AG
2004 Sportsman 500 Parts Manual rev.1
A04CH50AO
A04CH50AQ
A04CH50AR
A04CH50AS
A04CH50AT
A04CH50AV
A04CH50AW
2004 Sportsman 600 Parts Manual rev.2
A04CH59AF
A04CH59AH
A04CH59AJ
A04CH59AT
A04CH59AV
2004 Sportsman 600 Parts Manual rev.1
A04CH59AK
A04CH59AL
A04CH59AN
A04CH59AW
2004 Sportsman 600 and 700 Service Manual
2004 Sportsman 700 Parts Manual rev.2
A04CH68AC
A04CH68AF
A04CH68AH
A04CH68AJ
A04CH68AT
A04CH68AV
2004 Sportsman 700 Parts Manual
A04CH68AK
A04CH68AL
A04CH68AN
A04CH68AO
2004 Sportsman 700 MV Parts Manual
A04CH68MB
2004 Sportsman 700 MV Service Manual
2004 Ranger 2X4 Parts Manual
A04RB42AA
2004 Ranger 4X4 Parts Manual
A04RD50AA
2004 Ranger 6X6 Parts Manual
A04RF50AA
2005 Sportsman 6X6 Parts Manual
A05CL50AA
2005 Sportsman 6X6 Owners Manual
2005 Sportsman 6X6 Service Manual
2005 Sportsman 400,500.600 and 700 Owners Manual
2005 Sportsman 400 Parts Manual
A05MH42AB
A05MH42AG
A05MH42AH
2005 Sportsman 400 and 500 Service Manual
2005 Sportsman 500 HO/INT'L Parts Manual
A05MH50AB
A05MH50AC
A05MH50AG
A05MH50AH
A05MH50FB
2005 Sportsman 600 Parts Manual
A05MH59AK
A05MH59AN
2005 Sportsman 700 Parts Manual
A05MH68AK
A05MH68AN
2005 Sportsman 700 EFI Parts Manual
A05MH68AC
A05MH68AS
A05MH68AU
A05MH68AW
2005 Sportsman 700 EFI and 800 EFI Service Manaul
2005 Sportsman 800 EFI Parts Manual
A05MH76AC
A05MH76AU
A05MH76AW
2005 Sportsman MV7 Parts Manaul
A05MH68AP
2005 Sportsman MV7 Service Manual
2006 Outlaw 500 Service Manual
2007 Sportsman 6X6 Service Manual
2007 Sportsman 450 Service Manual
2007 Sportsman 500 EFI Service Manual
2007 Sportsman 500 X2 EFI Service Manual
2007 Sportsman 700 Service Manual
2007 Sportsman 800 Service Manual
2007 Sportsman 800 EFI Service Manual
2007 Sportsman 700 MV Parts Manual
A07MH68MA
2007 Sportsman 700 MV Service Manual
2007 Outlaw 500 Service Manual
2007 Ranger 700 EFI 6X6 Parts Manual
R07RF68AD
R07RF68AF
2007 Ranger XP 4X4 Service Manual
2007 Ranger XP 6X6 Service Manual
2008 Sportsman 500 Service Manual
2008 Sportsman 500 EFI Service Manual
2008 Sportsman X2 500 EFI Service Manual
2008 Sportsman Touring 500 EFI Service Manual
2008 Sportsman X2 700 Service Manual
2008 Sportsman 800 EFI Service Manual
2008 Sportsman 800 Touring Service Manual
2008 Ranger 6X6 700 EFI Parts Manual
R08RF68AD
R08RF68AF
2009 Sportsman 6X6 800 EFI Service Manual
2009 Sportsman 90 Service Manual
2009 Sportsman 300 Service Manual
2009 Sportsman 400 HO Service Manual
2009 Sportsman 500 HO Service Manual
2009 Sportsman 500 EFI Service Manual
2009 Sportsman X2 500 EFI Service Manual
2009 Sportsman Touring 500 EFI Service Manual
2009 Sportsman 800 EFI Service Manual
2009 Sportsman X2 800 EFI Service Manual
2009 Sportsman Touring 800 EFI Service Manual
2009 Sportsman XP 550 Service Manual
2009 Sportsman XP 550 EPS Service Manual
2009 Sportsman XP 850 Service Manual
2009 Sportsman XP 850 EPS Service Manual
2009 Outlaw 90 Service Manual
2009 Outlaw 450 MXR Service Manual
2009 Outlaw 525 S Service Manual
2009 Outlaw 525 IRS Service Manual
2009 Predator 50 Service Manual
2009 Ranger RZR Service Manual
2009 Ranger RZR S Service Manual
2009 Ranger INT'L Service Manual
2009 Ranger 2x4 Service Manual
2009 Ranger 4x4 Crew Service Manual
2009 Ranger 6x6 Service Manual
2009 Ranger 500 4x4 EFI Service Manual
2009 Ranger RZR 170 Service Manual
2009 Ranger XP 700 4x4 Service Manual
2009 Ranger HD 700 4x4 Service Manual
2009 Scrambler 500 Service Manual
2009 Trail Blazer 330 Service Manual
2009 Trail Boss 330 Service Manual
2010 Ranger RZR Service Manual
2010 Ranger RZR S Service Manual
2010 Ranger INT'L Service Manual
2011 Ranger RZR SW Service Manual
2011 Ranger RZR Service Manual
2011 Ranger RZR S Service Manual
2011 Ranger RZR 4 Service Manual
Other Stuff
2500lb Polaris Winch Install Instructions and Parts List
2500lb Warn Winch Install Instructions
2500lb Warn Winch Parts Manual
Warn Winch Motor Rotation Instructions
Warn - The Basic Guide to Winching Techniques
Sportsman 600 and 700 Ignition Replacement Kit Install Instructions
Polaris Special Tools - ATV,Snowmobile,Watercraft
Download Manuals HERE
Some ATV manuals available in the downloads section at https://www.quadcrazy.com/files/
Find them on on:
Get 15% at emanualsonline.com with coupon code EMOAFF
Get 20% at emanualsonline.com with coupon code BLAZE and $50 purchase
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By Ahren Longo
Yeah I know its been a while since I've been on but, I've recently aquired a 2005 Polaris ATP 500. As ya'll well know I'm sure that these things are notorious for faulty ECMs and they are made of unobtanium. I got this one from my brother. I've unpotted the old ECM and tested the components and have concluded that they don't flow the board properly from the factory so that's why they crap out. I've also done some research and found that if you take the harness and Stator and flywheel from a 2004 its basically a plug & play application and it eliminates the need for the ECM. Why the heck they put it in anyways is beyond me. I'm going to devise a way to make a plug & play adapter harness that eliminates the need for the ECM and restores the wheeler to use. Has anyone tried this before and had any luck? I've been trying to locate a wiring diagrams online so I can compare the 2004 to the 2005 but they're pretty hard to find.
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By jwline
Friday evening went riding, rode for a good hour or so everything was fine. I went to take a short ride to the restroom (less than 100 yds away) and all of the sudden everything flickered and then just died out. Accompanying the problem I noticed the killswitch completely locked up. Once daylight hit took the killswitch apart to find it had shorted out and melted the plastic inside. Has anyone else had anything similar to this and if so what did you do to fix the situation? I have a new killswitch on the way to replace the obvious problem but was wondering could there be a bigger issue at hand. We tested with a voltage meter to make sure everything was still getting power from the battery and as far as we could tell it was.
Any advice/info would be GREATLY appreciated.
Thanks.
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By bodon
Anyone know what the fuse terminal marked UNSWITCH does . Even with the key off it is causing a drain on my battery and I'm trying to figure out what that terminal goes to. It's a 10 amp fuse. If I pull it the "short" goes away. Thanks in advance.
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By Outkast7222
Had a spark-plug break off, had to pull the head to get it extracted. Where the heck is the timing mark on the crank? Do I need to pull the stator or flywheel to find it? When I pulled the head I had the mark on the cam lined up pretty good but I cant remember if it was perfect and don't want to reassemble a tooth off and have to go back through the bear of pulling this thing back apart.
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By Chase Cook
Hi I just got an Polaris sportsman 500 4x4 ATV the other day. I got it real cheap but I started to go into it because it didn't have compression so I bought a new piston and ring kit for it and installed it, but now when I try to start it all it does is shoot fire out the exhaust or the intake of the carburetor. And a timing is top dead center.;I think I can't really tell another way if it is or not. when I put it together I made sure to piston was on top and the cam lobes where facing down where are the cam sprocket is facing up. It has gas and spark. It did start a couple minutes ago but it didn't stay running and now it won't start. Do you think the valve need to be adjusted more to close better?I'm fixing to try that out and if that don't work what is the problem? Also I made sure everything was together good and right and change the oil and changed out the radiator fluid.
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By Brian Sosebee
I just rebuilt my 03 sportsman 400. Put everything back together added oil per the manual. Pinched off the oil tank vent line 2" away ran for 45 seconds then cut it off. Check oil level and it was still way high so I wasn't confident that it primed so I did it again. Checked again and it's the same. Remove the oil filter and it is dry. I did the procedure again and the same results.
I'm worried to keep trying this as the only oil in the engine is what I used to lubricate the parts when reassembling the piston. The crankcase was drained as well.
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