Polaris Sportsman 400 HO 2011 Factory Service & Work Shop Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2011 SPORTSMAN 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2011 SPORTSMAN 500 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2011 SPORTSMAN 500 HO TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2011 SPORTSMAN FOREST TRACTOR 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.2 GENERAL INFORMATION 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. Vehicle Identification Number (VIN) Transmission I.d. Location Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Engine And Machine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. The machine serial number is stamped on the lower left side of the frame tube (B). A 11 MN 50 AX } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier  Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 4 X A M N 5 0 A * 0 P 0 0 0 0 0 0 The transmission I.D.number is located on RH side of the transmission case, on right side A B

1.3 GENERAL INFORMATION 1 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. Publications Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required. Year Model Model No. Owner's Manual PN Parts Manual PN 2011 Sportsman Touring 500 H.O. A11DH50AX A11DH50AZ 9922809 9923059 2011 Sportsman Touring 500 H.O. International A11DH50FX 9922814 9923061 2011 Sportsman 400 H.O. A11MH46AX A11MH46AZ 9922803 9923090 2011 Sportsman 500 H.O. A11MH50AX A11MH50AZ 9922803 9923091 2011 Sportsman Forest 500 International A11MH50FF 9923174 9923320 2011 Sportsman Forest Tractor 500 EFI International A11MN50ET 9922810 9923095 PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman Frame Black 9440 P-067 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Cover PN 5433534

1.4 GENERAL INFORMATION 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. VEHICLE SPECIFICATIONS 2011 Sportsman 400 H.O. MODEL NUMBER: , A11MH46AX, AZ ENGINE MODEL: EH460PLE050 Category Dimension Length 83 in. / 210.8 cm Width 48 in. / 121.9 cm Height 48 in. / 121.9 cm Wheel Base 50.5 in. / 117 cm Dry Weight 688 lbs. / 312 kg Gross Vehicle Weight 1260 lbs. / 516.1 kg Front Rack Capacity 90 lbs. / 48 kg Rear Rack Capacity 180 lbs. / 81.6 kg Towing Capacity 1225 lbs. / 555.7 kg Max. Weight Capacity 450 lbs. / 166 kg Hitch Tongue Weight 120 lbs. / 34 kg Unbraked Trailer Towing Capacity (EU) Data based on EU Directive: 76/432/EEC 1785.7 lbs. / 810 kg Engine Platform Fuji 4-cycle, L/C, Single Cyl. Engine Model Number EH460PLE050 Engine Displacement 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio 10.1:1 Compression Pressure 50-90 psi Engine Idle Speed 1100 +/- 50 RPM Cooling System / Cap. Liquid / 2.7 qt. (2.5 L) Overheat Warning HOT on Instrument Cluster Lubrication Dry Sump Oil Requirements PS-4 Plus / 2 qt. (1.9 L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 160 Pilot Jet / Pilot Air Jet 42.5 / 160 Jet Needle 4IB33-3 Needle Jet P-6M Pilot / Air Screw 2.75 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump (Impulse) Fuel Capacity / 4.1 gal. (15.5 L) Fuel Requirement (Octane) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 260 watt @ 3000 RPM Voltage Regulator 3-Phase PDM Pod Lighting 1x 12V / 50 Watts Grill Lighting 2x 12v / 50 Watts Brake Light 12V / 26.9 watts Tail Light 12V / 8.26 watts Ignition System DC / CDI Ignition Timing 14° ± 2° BTDC @ 1500 RPM 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E / .035 in. (.9 mm) Battery Maintenance-Free / 12 Amp Hr. Circuit Breakers 10A - Accessory / 10A - Fan / 15A - Main Harness Starting Electric / Recoil Back-up Instrument Cluster Digital Gauge LCD, Analog Speedometer

1.5 GENERAL INFORMATION 1 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. JETTING CHART Drivetrain Transmission Type In-Line H/L/N/R/P Transmission Fluid Type / Fluid Capacity AGL Plus 33.8 oz. (1000 ml) Front Gearcase Fluid Type / Fluid Capacity Polaris Demand Drive Hub Fluid / 8.97 oz / 265 ml Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear) 7.70:1/23.91:1 7.00:1/21.74:1 3.41:1/10.75:1 Clutch Type CVT Belt 3211077 Steering / Suspension Front Suspension / Shock MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock IRS / Progressive Rate Rear Travel 9.5. / 24.1 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Toe Out 0-1/16 in. (0-.159 mm) Wheels / Brakes Front Wheel Size Front Tire Model / Size 12x5 Titan 489 / 25 x 8-12 Rear Wheel Size Rear Tire Model / Size 12x8 Titan 489 / 25 x 11-12 Tire Air Pressure - F / R 5 psi (34.5 kPa) Brakes - Front & Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid ALTITUDE AMBIENT TEMPERATURE Below 40° F Below 5° C Above +40° F Above +5° C Meters (Feet) 0-1800 (0-6000) 167.5 160 1800-3700 (6000- 12000) 155 150 Table 1-1: Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Type (Non-Adjustable) Meters (Feet) 0-1800 (0-6000) 10WH 5630710 Black 7043594 Blk / Almond 7043167 1800-3700 (6000- 12000) 20-40 or 10RH 5631356 (20-40) 5630709 (10RH)

1.6 GENERAL INFORMATION 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. 2011 Sportsman 500 H.O. MODEL NUMBER: A11MH50AX, AZ, FF ENGINE MODEL: EH500PLE13B Category Dimension / Capacity Length 83 in./210.8 cm Width 48 in./121.9 cm Height 48 in./121.9 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 696 lbs./313 kg (Wet weight model FF 776 lbs / 352 kg) Gross Vehicle Weight 1266 lbs./574 kg (Model FF 1346 lbs / 610 kg.) Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Max. Weight Capacity 450 lbs. / 166 kg Towing Capacity 1225 lbs ./ 555.7 kg Unbraked Trailer Towing Capacity (EU)* NOTE: *Data based on EU Directive: 76/432/EEC 1785.7 lbs. / 810 kg Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg ENGINE Platform Fuji Single Cylinder Engine Model Number EH500PLE13B Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression Release Engine Idle Speed 1100 ± 50 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Carburetor Mikuni BST 40mm Main Jet 150 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 2 Turns Out (initial) Pilot Air Jet 40 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.1 gal US / 15.5 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 260 w @ 3000 RPM Voltage Regulator 3-phase PDM Lights : Pod 50 watts Grill 2 x 50 watts Brake 26.9 watts Tail 8.26 watts Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery Maintenance-Free / 12 Amp Hr. Circuit Protection 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD

1.7 GENERAL INFORMATION 1 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. Table 1-2: Sportsman 500 H.O. Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz. (1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear) 7.70:1/23.91:1 7.00:1/21.74:1 3.41:1/10.75:1 Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen- dent - w/ 2" Coil-over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pres- sure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-3: Sportsman 500 H.O. Jetting Altitude AMBIENT TEMPERATURE Below 40 ° F Below 5 ° C +40 to +80 ° F +5 to +28 ° C Meter s (Feet) 0-1800 (0-6000) 155 150 1800-3700 (6000- 12000) 147.5 142.5 Table 1-4: Sportsman 500 H.O. Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Meter s (Feet) 0-1800 (0-6000) 10 WHF (56322 83) Blu/ Grn (70411 57) Black (70417 82) 41-37° 2+2 (51323 44) 1800-3700 (6000- 12000) 10 RH (56307 09 Blu/ Grn (70411 57) Black (70417 82) 41-37° 2+2 (51323 44)

1.8 GENERAL INFORMATION 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. 2011 Sportsman 500 HO Touring MODEL NUMBER: A11DH50AX, AZ, FX ENGINE MODEL: EH500PLE13B Category Dimension / Capacity Length 86 in./218 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 770 lbs./349 kg (Wet weight model FX 791 lbs. / 359 kg.) Gross Vehicle Weight 1340 lbs./607.8 kg (Model FX 1361 lbs. / 617 kg.) Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./82 kg Towing Capacity 1225 lbs. / 555.7 kg Unbraked Trailer Towing Capacity (EU)* NOTE: *Data based on EU Directive: 76/432/EEC 1995 lbs. / 905 kg Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg ENGINE Platform Fuji Single Cylinder Engine Model Number EH500PLE13B Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression Release Engine Idle Speed 1100 ± 50 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Carburetor Mikuni BST 40mm Main Jet 150 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 2 Turns Out (initial) Pilot Air Jet 160 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.1 gal US / 15.5 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 260 w @ 3000 RPM Lights : Pod 50 watts Grill 2 x 50 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 30°± 1 BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery Maintenance-Free / 12 Amp Hr. Circuit Breakers 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD

1.9 GENERAL INFORMATION 1 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. Table 1-5: Sportsman Touring 500 H.O. Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz. (1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear) 7.70:1/23.91:1 7.00:1/21.74:1 3.41:1/10.75:1 Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen- dent - w/ 2" Coil-over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pres- sure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-6: Sportsman 500 H.O. Jetting Altitude AMBIENT TEMPERATURE Below 40 ° F Below 5 ° C +40 to +80 ° F +5 to +28 ° C Meter s (Feet) 0-1800 (0-6000) 155 150 1800-3700 (6000- 12000) 147.5 142.5 Table 1-7: Sportsman 500 H.O. Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven- Helix Meter s (Feet) 0-1800 (0-6000) 10 WHF (56322 83) Blu/ Grn (70411 57) Black (70417 82) 41-37° 2+2 (51323 44) 1800-3700 (6000- 12000) 10 RH (56307 09 Blu/ Grn (70411 57) Black (70417 82) 41-37° 2+2 (51323 44)

1.10 GENERAL INFORMATION 9923060 - 2011 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2010 Polaris Sales Inc. 2011 Sportsman Forest Tractor 500 EFI Specifications MODEL NUMBER: A11MN50ET ENGINE MODEL: EH500PLE216 NOTE: *Data based on EU Directive: 76/432/EEC Category Dimension / Capacity Length 83 in./210.8 cm Width 48 in./121.9 cm Height 48 in./121.9 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm WET Weight 842 lbs. / 382 kg Gross Vehicle Weight 1412 lbs. / 640 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Max. Weight Capacity 450 lbs. / 166 kg Towing Capacity 1225 lbs ./ 555.7 kg Unbraked Trailer Towing Capacity (EU)* 1785.7 lbs. / 810 kg Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg ENGINE Platform Fuji 4 stroke, Single Cylinder Engine Model Number EH500PLE216 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure Compression Release 50-90 psi Engine Idle Speed 1100 ± 200 RPM Cooling System / Capacity Liquid / 2.7 qts (2.5 L) Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 / 2 qts (1.9L) Exhaust System Single Pipe Fuel System Carburetor model Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25 Liters per hour at 39 psi Fuel Filters 30 micron in-tank Fuel Injector Visteon EFI Controller Visteon Fuel Capacity / Requirement 4.13 gal. (15.6 L) 87 (minimum) 89 Oxygenated Electrical Alternator Output 350 watt @ 5000 RPM Voltage Regulator 3-phase Lights : High Beam 50 watts Low Beam 37 watts Brake 26.9 watts Tail 8.26 watts Parking Lights 5 watts x 2 Turn 10 watts Ignition System DC/CDI Ignition Operating RPM (torque) 5500 RPM Ignition Timing 10°± 1° BTDC @ Idle RPM Spark plug / Gap NGK BKR6E .035 in. / .9 mm Battery / Amp Hr Lead Acid - 30 Amp Hr Circuit Breakers Fan 20 Amp Harness 20 Amp Fuel Pump-ECU 15 Amp Instrument Cluster-Voltage Regulator 6 Amp Starting Electric Instrument Cluster LCD Gauge / Pod Indicator lights

Polaris Sportsman 400 HO 2011 Factory Service & Work Shop Manual

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