Polaris Head Gasket 3084797 1994-1999 300 Xplorer Xpress

1994 300 2X4 (W947530) – Crankcase & Cylinder 2X4 300
1994 300 4X4 (W948130) – Crankcase & Cylinder 4X4 300
1994 300 6X6 (W948730) – Crankcase & Cylinder 6X6 300
1994 ) S948740 SWEDISH 400L 6X6 (1994) (S948740) – Crankcase & Cylinder 2X4 300 W947530 (4926742674C007)
1994 ) S948740 SWEDISH 400L 6X6 (1994) (S948740) – Crankcase & Cylinder 6X6 300 W948730 (4926792679D003)
1994 ) W948130 300 4X4 (1994) (W948130) – Crankcase & Cylinder 4X4 300 W948130 (4926762676C012)

Fits Polaris:
300 2×4 (94 & 95)
300 4×4 (94 & 95)
300 6×6 (94)
Xplorer 300 4×4 (96-99)
Xpress 300 (96-99) 3084797

2003 – 2004 Polaris Scrambler Trail Blazer Boss Rear Brake Pads 2202411

Original Polaris factory parts, part number 2202411 rear brake pads for the following models:
2003 SCRAMBLER 500 4X4 (A03BG50AA) – Rear Caliper Mounting
2003 TRAIL BLAZER 250 (A03BA25CA/CB) – Rear Caliper Mounting
2003 TRAIL BLAZER 400 (A03BA38CA) – Rear Caliper Mounting
2003 TRAIL BOSS 330 (A03CA32AA) – Rear Caliper Mounting
2003 ) A03BA25CA/CB TRAIL BLAZER 250 (2003) (A03BA25CA/CB) – Rear Caliper Mounting – A03ba25ca/Cb (4986208620B05)
2003 ) A03CB32AA MAGNUM 330 2X4 (2003) (A03CB32AA) – Rear Caliper Mounting – A03ba38ca (4986208620B05)
2003 ) A03CB32AA MAGNUM 330 2X4 (2003) (A03CB32AA) – Rear Caliper Mounting – A03bg50aa (4986228622B13)

2003 ) A03CB32AA MAGNUM 330 2X4 (2003) (A03CB32AA) – Rear Caliper Mounting – A03ca32aa (4986248624B02)
2004 A04BA25CA TRAIL BLAZER (A04BA25CA/CB) – Rear Caliper Mounting
2004 A04BG50AA SCRAMBLER 500 4X4 (A04BG50AA/FA) – Rear Caliper Mounting
2004 A04CA32AA TRAIL BOSS 330 (A04CA32AA/AB/FA) – Rear Caliper Mounting
2004 ) A04BA25CA TRAIL BLAZER (2004) (A04BA25CA/CB) – Rear Caliper Mounting – A04ba25ca/Cb (4986208620B05)
2004 ) A04BA25CA TRAIL BLAZER (2004) (A04BA25CA/CB) – Rear Caliper Mounting – A04bg50aa/Fa (4986228622B13)
2004 ) A04BA25CA TRAIL BLAZER (2004) (A04BA25CA/CB) – Rear Caliper Mounting – A04ca32aa/Ab/Fa (4986248624B02)

22024112202411a

2000 – 2001 Polaris Int. Big Boss Sportsman 6×6 335 Rear Brake Pads 2201685

Original OEM Brake pads by Polaris fit the following models:

2000 INT’L BIG BOSS (A00CL50DA) – Rear Brake Caliper – A00cl50aa
2000 SPORTSMAN 6X6 (A00CL50AA) – Rear Brake Caliper
2000 ) A00CH33AC SPORTSMAN 335 (2000) (A00CH33AC) – Rear Brake Caliper – A00cl50aa (4954815481B012)

2001 INT’L BIG BOSS 6X6 (A01CL50DA) – Rear Brake Caliper – A01cl50aa
2001 SPORTSMAN 6X6 (A01CL50AA) – Rear Brake Caliper
2001 ) A01AA32AA TRAIL BOSS (2001) (A01AA32AA) – Rear Brake Caliper – A01cl50aa (4964586458B010)

2201685

Polaris Scrambler Trail Blazer Cyclone Boss Repair Service Manual 1985 – 1995

This manual covers 3-, 4- and 6-wheel models with 250-425cc models including:
Scrambler 250 (1985-1986)
Scrambler 400 (1995)
Trail Blazer 250 (1990-1995)
Trail Boss 250 (1985-1987, 1994)
Trail Boss 250 2X4 (1988-1993)
Trail Boss 250 4X4 (1987-1993)
Trail Boss 250ES (1988)
Trail Boss 250R (1988)
Trail Boss 300 2X4 (1994-1995)
Trail Boss 300 4X4 (1994-1995)
Trail Boss 350L 2X4 (1990-1993)
Trail Boss 350L 4X4 (1990-1993)
Trail Boss 400L 2X4 (1994-1995)
Trail Boss 400L 4X4 (1994)
Cyclone 250 (1987)
Big Boss 250 4X6 (1988-1992)
Big Boss 250 6X6 (1991-1993)
Big Boss 300 6X6 (1994)
Big Boss 350 6X6 (1993)
Big Boss 400L 6X6 (1994)
Xplorer 300 6X6 (1995)
Xplorer 400 4X4 (1995)
Xplorer 400L 6X6 (1995)
Sport 400L (1994-1995)
Sportsman 400 4X4 (1994-1995)
Magnum 2X4 (1995)
Magnum 4X4 (1995)

This Polaris ATV manuals is 424 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Service hints / Torque specifications / Safety first / Expendable supplies / Engine and chassis serial numbers / Basic hand tools / Precision measuring instruments / Special tips / Mechanic’s tips / Operating tips / RTV sealant / Threadlock / Gasket remover / Parts replacement / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Electrical testing / Power train / Steering / Engine electrical system troubleshooting / Voltage regulator / Speed limiter

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checks / Service maintenance intervals schedule / Fluid checks / Break-in / Periodic lubrication / Engine oil and filter change / Control cable lubrication / Engine counter balancer / Transmission oil change / Rear axle housing lubrication / Periodic maintenance / Drive belt chain adjustment check / Oil injection pump adjustment / General inspection and maintenance / Toe-in adjustment / Tune-up / Cylinder head blot torque / Cylinder compression check / Spark plug / Ignition timing / Cam chain adjustment / Valve clearance / Carburetor adjustment / Idle speed / Storage / Specifications

CHAPTER FOUR / ENGINE (2-STROKE MODELS)
Removal installation / Liquid cooling / Cylinder head / Cylinder / Reed valve assembly / Piston, piston pin and rings / Recoil starter / Coolant pump / Engine balancer / Crankcase / Crankshaft, bearings and shim / Oil injection system / Break-in / Specifications

CHAPTER FIVE / ENGINE (4-STROKE MODELS)
Engine cooling / Engine lubrication / Removal installation / Cylinder head cover and rocker arm assembly / Camshaft / Cylinder head / Cylinder / Piston, pin and rings / Cam chain, sprockets and tensioner / Recoil starter / Flywheel and stator plate / Coolant pump / Crankcase / Crankshaft, balance shaft, bearings and seals / Oil pump / One way check valve / Break-in procedure / Specifications

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor / Throttle cable / Choke cable / Fuel tank / Fuel shutoff valve / Air box / Fuel pump / Exhaust system / Specifications

CHAPTER SEVEN / COOLING SYSTEM
Polaris variable transmission PVT cooling system / Engine cooling air cooled models / Engine cooling liquid cooled models / Specifications

CHAPTER EIGHT / CLUTCH/DRIVE BELT SYSTEM
Drive unit / Drive pulley assembly / Driven pulley / Drive belt / Clutch inner cover / Specifications

CHAPTER NINE / TRANSMISSION SYSTEM
Type I transmission / Type II transmission / Type III transmission / Specifications

CHAPTER TEN / FRONT DRIVE SYSTEM
Front hubs / Front drive shaft boots and CV joints / Center chain and sprockets / Front chain and sprockets / Specifications

CHAPTER ELEVEN / ELECTRICAL SYSTEM
Charging system / Alternator stator / Voltage regulator/rectifier / Capacitor discharge ignition / Ignition high tension coil /Ignition stator coils exciter and pulser / Electric starting system / Starter drive gears / Starter solenoid / Lighting system / Switches / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Front fork tubes / Front suspension / Steering shaft / Tires and wheels / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Rear wheels / Rear tires / Rear axle / Drive chain / Drive and driven sprockets / Tire changing and tire repairs / Shock absorber / Rear swing arm / Specifications

CHAPTER FOURTEEN / BRAKES
Front brakes / Hydraulic brakes / Front brake caliper / Mechanical rear brake caliper / Hydraulic rear caliper / Master cylinder / Brake hose / Brake disc / Brake bleeding / Specifications

CHAPTER FIFTEEN / BODY
Seat / Fuel tank cover / Front panel / Front fender / Rear fender / Side panels / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 Polaris 250 – 425 cc 3-wheel models
1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 Polaris 250 – 425 cc 4-wheel models
1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 Polaris 250 – 425 cc 6-wheel models
Scrambler, Trail Blazer, Trail Boss, Cyclone, Big Boss, Xplorer, Sport, Sportsman, Magnum

496496b496p

Polaris Predator 500 Troy Lee Designs 2003 2007 Service Repair Manual M367

Polaris Predator 500 (2003-2007)
Polaris Predator 500 (Troy Lee Designs) (2005-2006)

This Polaris Predator manual is 352 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Front suspension and steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Air box drain plugs / Air filter / Engine oil and filter change / Oil pressure test / Spark plug / Spark arrester cleaning / Fuel tank vent hose / Fuel hose inspection / Carburetor / Choke adjustment / Tune-up / Ignition timing / Valve clearance / Compression test / Control cables / Cooling system / Skid plate inspection / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine service / Cylinder head cover / Camshaft / Camshaft chain tensioner / Camshaft chain, timing sprocket and chain guides / Cylinder head / Valve lifters and shims / Valves and valve components / Cylinder block / Piston and piston rings / Break-in procedure / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Crankcase / Water pump mechanical seal and bearing replacement / Crankshaft / Balancer shaft inspection / Primary drive gear / Oil pump / One-way check valve / Oil tank, oil pipe and hoses / Break-in procedure / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Right crankcase cover / Clutch / Cable / External shift mechanism / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM (2003-2004 MODELS)
Transmission and internal shift mechanism / Transmission inspection / Specifications

CHAPTER EIGHT / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM (2005-ON MODELS)
Transmission and internal shift mechanism / Transmission inspection / Internal shift mechanism inspection / Reverse gear arm shifter / Specifications

CHAPTER NINE / FUEL AND EXHAUST SYSTEMS
Carburetor / Pilot screw / Carburetor tests and adjustments / Throttle cable / Choke cable / Fuel tank / Fuel shutoff valve / Air box / Fuel pump / Exhaust system muffler spark arrester / Specifications

CHAPTER TEN / ELECTRICAL SYSTEM
Electrical connectors / Battery / Charging system / Voltage regulator rectifier / Capacitor discharge ignition CDI / Alternator cover and stator coil / Alternator rotor and starter gears / Ignition coil / Starter / Starter solenoid / Lighting system / Switches / Cooling system fan switch and sensor / Circuit breaker / Specifications

CHAPTER ELEVEN/ COOLING SYSTEM
Coolant reservoir / Radiator / Cooling fan / Water pump / Thermostat / Cooling fan switch / Engine coolant temperature sensor / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Shock absorber / Tie rods / Front spindle / Control arms / Center link and idle arm (2003-2006 models) / Handlebar / Steering shaft / Tires and wheels / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Rear wheel / Rear hub / Rear axle / Rear axle eccentric / Drive chain / Sprockets / Shock absorber / Swing arm / Specifications

CHAPTER FOURTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper (2003-2006 models) / Front caliper (2007 models) / Front master cylinder / Rear brake pad replacment / Rear caliper (2003-2006 models) / Rear caliper (2007 models) / Rear master cylinder / Brake hose replacement / Rear brake pedal / Brake disc / Brake bleeding / Specifications

CHAPTER FIFTEEN / BODY
Side panels / Front fender / Rear fender / Heel pocket and mounting bracket / Specifications

INDEX

COLOR WIRING DIAGRAMS

Models covered:
2003 2004 2005 2006 2007 Polaris Predator 500
2005 2006 Polaris Predator 500 (Troy Lee Designs)

367367b367p

Polaris Sportsman 600 700 800 2002 – 2010 Service and Repair Manual M366

MODELS COVERED
Sportsman 600 2003-2005
Sportsman 700 2002-2006
Sportsman 700 EFI 2004-2007
Sportsman 700 EFI X2 2008
Sportsman MV7 2005-2006
Sportsman 800 EFI 2005-2010
Sportsman 800 EFI X2 2007-2009
Sportsman 800 EFI Touring 2008-2009
This Clymer repair manual is for the Polaris Sportsman 600 (2003-2005), Sportsman 700 (2002-2006), Sportsman 700 EFI (2004-2007), Sportsman 700 EFI X2 (2008), Sportsman MV7 (2005-2006), Sportsman 800 EFI (2005-2010), Sportsman 800 EFI X2 (2007-2009), Sportsman 800 EFI Touring (2008-2009). Clymer makes a great book and this is as good as they get. Everything you need for routine maintenance, engine overhaul and the list goes on.
TABLE OF CONTENTS

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and note / Safety / Serial numbers / Model identification (2004 models) / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Warning light system / Starting the engine / Engine will not start / Starting difficulties / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Electrical testing / Electrical troubleshooting / Meter assembly/Front gearcase / Steering / Steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule / Pre-ride inspection / Tune-up / Engine compression test / Engine oil and filter / Oil pressure test / Clutch / Transmission oil / Shift linkage / Air filter / Inline breather filter / Air intake ducts / Idle speed (carbureted models) / Control cables / Fuel system / Exhaust system / Ignition timing (2002-2004 carbureted models) / Spark plugs / Cooling system / Front gearcase oil / Rear gearcase oil (all models except X2 and Touring models) / Tires and wheels / Steering system / Suspension / Brake system / Lighting system/Recoil starter / Lubrication service / Fasteners / Wires, hoses and control cables / Specifications

CHAPTER FOUR / ENGINE TOP END
Component identification / Rocker cover / Rocker arms and pushrods / Cylinder head / Cylinder block and pistons / Valve lifter / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine service / Oil system priming / Engine removal / Engine installation / Recoil starter (MV7 models) / Alternator covers (all models except MV7) / Flywheel, bendix and stator / Water pump cover / Stator housing / Timing gears / Water-oil pump / Camshaft thrust plate / Crankcase / Engine break-in / Specifications

CHAPTER SIX / CLUTCH AND DRIVE BELT SYSTEM
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Clutch outer cover / Clutch inner cover / Drive clutch / Driven clutch / Specifications

CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM (ALL MODELS EXCEPT X2 and TOURING MODELS)
Gearshift selector / Transmission case / Transmission / Specifications

CHAPTER EIGHT / TRANSMISSION AND SHIFT MECHANISM (X2 and TOURING MODELS)
Gearshift selector / Transmission case / Transmission shafts / Differential gear assembly / Snorkel shaft / Specifications

CHAPTER NINE / AIR/FUEL AND EXHAUST SYSTEMS (CARBURETED MODELS)
Air box / Exhaust system / Intake manifold / Carburetor / Carburetor tests and adjustments / Pilot screw / Throttle cable / Throttle lever housing / Choke (starter) cable / Fuel draining / Fuel valve / Fuel tank / Rear tank (2005-on MV7 models) / Fuel sender (later 2004-on 600 and 700 models, 2005-on MV7 models) / Fuel pump / Specifications
CHAPTER TEN / AIR/FUEL SYSTEM (FUEL INJECTED MODELS)
Air box / Exhaust system / Exhaust manifold / Priming the Fuel System / Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel sender / Pressure regulator / Throttle lever housing / Throttle cable / Throttle body / Fuel injectors / Crankshaft position (CKP) sensor / Temperature and barometric air pressure (T-BAP) sensor / Throttle position sensor (TPS) / Electronic control unit (ECU) / Self diagnosis / Specifications

CHAPTER ELEVEN / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Charging system / Stator / Voltage regulator-rectifier / Logic box (2005-on carbureted models) / Relays / Ignition system identification / CDI unit / Trigger coil / Ignition coil / Electronic control unit (ECU) / Starting system/Starter / Starter solenoid / Electronic throttle control (ETC) switch / Headlight pod/Headlight / Taillight assembly / Work light (models so equipped) / Switches / All wheel drive (AWD) coil / Active descent control (ADC) coil / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit / Differential solenoid (X2 and Touring models) / Differential controller relay (X2 and Touring models) / Meter assembly / On-board diagnosis / Fuses / Wiring and connectors / Wiring diagrams / Specifications

CHAPTER TWELVE / COOLING SYSTEM
Hoses and hose clamps / Cooling system inspection / Coolant reservoir / Radiator / Radiator fan / Fan switch (2002-2004 600 and 700 models) / Coolant temperature sensor / Thermostat / Water pump / Specifications

CHAPTER THIRTEEN / WHEELS, TIRES AND HUBS
Wheels / Front hub / Front bearing carrier / Rear hub / Rear bearing carrier / Tires / Specifications
CHAPTER FOURTEEN / FRONT SUSPENSION, STEERING AND FRONT DRIVE SYSTEM
Hubstrut / Front strut / A-arm / Tie rod / Steering post / Handlebar / Handlebar grip / Front drive axle / Front drive shaft / Universal joint / Front gearcase / Specifications

CHAPTER FIFTEEN / REAR SUSPENSION AND REAR DRIVE SYSTEM
Shock absorber / Upper control arm / Lower control arm / Control arm inspection / Stabilizer linkage assembly / Stabilizer support / Rear drive axle / Rear gearcase (all models except X2 and Touring models) / Rear drive shaft (all models except X2 and Touring models) / Specifications

CHAPTER SIXTEEN / BRAKES
Brake operation / Brake service notes / Brake bleeding / Brake fluid draining / Brake pad inspection / Front brake caliper / Rear brake caliper / Front brake master cylinder / Rear brake master cylinder / Brake pedal / Brake disc / Brake hoses / Specifications

CHAPTER SEVENTEEN / BODY AND FRAME
Quick release inserts / Rider’s seat / Rider’s backrest and passenger seat (X2 models) / Passenger seat (Touring models) / Side panel / Fender cover / Front fender / Front rack / Front bumper (all models except MV7) / Front brush guard / Grill and radiator shield (all models except MV7 models) / Rear rack (all models except MV7, X2 and Touring models) / Rear rack (Touring models) / Rear rack and brush guard assembly (MV7 models) / Rear quarter panel (X2 models) / Footwell / Rear storage box (all models except M2 models) / Cargo box (X2 models) / Winch / Winch contactor / Specifications

INDEX

WIRING DIAGRAMS

366366b

Polaris 400 450 500 Sportsman HO RSE 1996-2013 Service Repair Manual M365-5

Sportsman 400 2001-2005
Sportsman 450 2006-2007
Sportsman 450 Browning Edition 2006
Sportsman 500 1996-2010
Sportsman 500 DUSE 2001-2002
Sportsman 500 HO 2001-2006, 2008-2010
Sportsman RSE 2000-2002
Sportsman 500 X2 2006-2010
Sportsman 500 Touring
2008-2010
Worker 500 1997-2001
Xplorer 500 1997

This brand new Clymer repair manual is for the Polaris Sportsman 400 (2001-2005), Sportsman 450 (2006-2007), Sportsman 450 Browning Edition (2006), Sportsman 500 (1996-2010), Sportsman 500 DUSE (2001-2002), Sportsman 500 HO (2001-2006, 2008-2010), Sportsman 500 RSE (2000-2002), Sportsman 500 X2 (2006-2010), Sportsman 500 Touring (2008-2010), Worker 500 (1997-2001) and Xplorer 500 (1997). This manual is 715 pages, catalog number M365-5 and the latest edition available!

Every Clymer manual contains hundreds of original photographs and exploded parts views developed from a complete disassembly and assembly of the ATV. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy, and clarity.

Designed for the reader who may be working on the ATV for the first time, the step-by-step instructions and two-column text with large print is user friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb tabbed chapters; numbered table of contents and extensive index make it possible to locate the desired section quickly. And unlike a factory manual, this Clymer manual is written specifically for the DIY enthusiast.

TABLE OF CONTENTS

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Model identification (2004 models) / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Gearshift linkage / Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil / Oil pump priming / Oil pressure test / Transmission / Front gearcase oil / Front hub (1996-early 2004 models) / Clutch / Air filter / Fuel tank vent hose / Fuel hose and filter / Brake system / Control cables / Cooling system / Exhaust system / Suspension / Tires and wheels / Lubrication service / Fastener inspection / Valve clearance / Compression test / Spark plug / Ignition timing / Idle speed / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine service / Engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications

CHAPTER FIVE / ENGINE LOWER END
Flywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications

CHAPTER SIX / CARBURETOR AND FUEL SYSTEM
Carburetor operation / Carburetor / Carburetor tests and adjustments / Throttle cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump / Specifications

CHAPTER SEVEN / FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and fuel injector / Fuel pump / Fuel sender / Pressure regulator / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position sensor (TPS) / Engine coolant temperature (ECT) sensor / Electronic control module (ECM) / Self diagnosis / Throttle cable replacement / Air filter air box / Specifications

CHAPTER EIGHT / COOLING SYSTEM
Air cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications

CHAPTER NINE / CLUTCH AND DRIVE BELT
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications

CHAPTER TEN / TRANSMISSION (1996-EARLY 2004 MODELS)
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase oil seal inspection and replacement / Shift selector linkage / Specifications

CHAPTER ELEVEN / TRANSMISSION (LATE 2004-ON MODELS)
Transmission / Transmission shafts / Differential gear assembly (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications

CHAPTER TWELVE / FRONT DRIVE SYSTEM
Front hub and Hilliard clutch (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front drive axle, boots and constant velocity (CV) joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent control (2007-on Sportsman 500, X2 and Touring models) / Specifications

CHAPTER THIRTEEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / Alternator stator / Voltage regulator/rectifier / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (fuel injected models) / Ignition coil / Electric starting system / Starter drive gears / Starter solenoid / Headlight system / Taillight and work light / Indicator lamp (1996-2002 models) / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit (late 2004-on models) / Differential solenoid (X2 and Touring models) / Switches / Electronic throttle control (ETC) switch / All wheel drive (AWD) coil / Active descent control (ADC) coil / (2007-on X2 and Touring models) / Cooling system switch and sensor / Fuses and circuit breaker (2008 models) / Speedometer / On-board diagnostics / Winch (models so equipped) / Winch contactor (models so equipped) / Specifications

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Front wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / Specifications

CHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / Lower control arm (X2 and Touring models) / Upper and lower control arm inspection / Stabilizer linkage (all models except X2 and / Touring) / Stabilizer support (all models except X2 and / Touring) / Stabilizer support and bar (X2 and Touring models) / Specifications

CHAPTER SIXTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper / Output shaft brake pad replacement / (1996-1997 models) / Output shaft brake caliper (1996-1997 models) / Output shaft brake pad replacement / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / Rear brake pad replacement (2003-on models / except X2 and Touring) / Rear caliper (2003-on models except X2 and / Touring) / Rear brake pad replacement (X2 and / Touring models) / Rear caliper (X2 and Touring models) / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake bleeding tips / Brake bleeding / Brake fluid draining / Rear brake pedal / Brake disc / Specifications

CHAPTER SEVENTEEN / BODY AND FRAME
Plastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Radiator guard (1996-2003 models) / Radiator brush guard (2004-on models) / Brush guard grill and radiator side shield / (2004-on models) / Rear rack, rail and bumper (1996-2002 models) / Rear rack and rail (2003-on except X2 and / Touring) / Rear rack and handle (Touring models) / Rear fender / Rear quarter panel (X2 models) / Footwell / Footwell support bracket (X2 and Touring models) / Rear storage box (all models except X2 and Touring) / Cargo box (X2 models) / Specifications

INDEX

COLOR WIRING DIAGRAMS
36553655b

Cobra Fi2000 EFI Tuner Polaris Sportsman 700 800 2005 – 2008

New in the box with factory warranty. Cobra Fi2000 Digital EFI Tuner / Plug and Play

Just because your ATV or off-road motorcycle is now fuel injected does not mean you will never have to adjust the air-fuel mixture. In fact, quite the opposite is true. Nearly every fuel-injected engine can benefit with the installation of the Fi2000. Better throttle response, no backfiring, and smoother cruising are just a few of the areas improved by the Fi2000. When your engine has the proper air/fuel ratio metered to it, it can perform to its potential, run cooler and deliver a much more satisfying ride. Our Fi2000 comes preset for your make and model of motorcycle or ATV. It is also set for your bike or ATV equipped with a high performance aftermarket exhaust system. This setting will enhance the performance of the entirely stock bike as well. If you add a high flow air filter system, you might need to adjust your particular model. Each comes with detailed instructions showing you how to make those adjustments quickly and easily. You can also contact our customer service staff to help you adjust your Fi2000 should your specific set of parameters require additional tuning.

Polaris Sportsman 700/800 2005 – 2008 / Does not plug and play with Touring Models

Part # 51-0551 ($229.95 Retail)51-0551