Polaris 400 and 500 Sportsman (2012) - Service Manual - Wiring Diagram View larger

Polaris 400 and 500 Sportsman (2012) - Service Manual - Wiring Diagram

English Service Manual and Wiring Diagram to ATVs Polaris 400 & 500 Sportsman (2012).

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LANGUAGE: English.
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PAGES: 432
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POLARIS 400 & 500 SPORTSMAN (2012) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual and Wiring Diagram to ATVs Polaris 400 & 500 Sportsman (2012).


CONTENTS:

CHAPTER 1 - GENERAL INFORMATION

MODEL NUMBER INFORMATION
-     Model Number
-     Vehicle Identification Number (VIN)
-     Engine Designation Numbers
-     Vehicle and Engine Serial Numbers
-     Transmission I.D. Location
-     Publication Part Numbers
Vehicle Specifications
-     2012 Sportsman 400 H.O.
-     2012 Sportsman 500 H.O.
-     2012 Sportsman Touring 500 HO
-     2012 Sportsman Forest Tractor 500 EFI Specifications MODEL NUMBER: A12MN50ET, EX
MISC. NUMBERS/CHARTS
-     Conversion Table
-     Standard Bolt Torque Specification
-     Metric Bolt Torque Specification
-     SAE Tap Drill Sizes
-     Metric Tap Drill Sizes
-     Decimal Equivalents
-     Paint Codes
-     Replacement Keys
-     Glossary Of Terms

CHAPTER 2 - MAINTENANCE

SPECIAL TOOLS
MAINTENANCE
-     Periodic Maintenance Chart
-     Maintenance Chart Key
-     Periodic Maintenance Chart
LUBRICANTS / SERVICE PRODUCTS
-     Polaris Lubricants, Maintenance and Service Products
LUBRICATION / FLUIDS
-     Pre-Ride / Daily Inspection
-     Lubrication Components
-     Front Gearcase Lubrication
-     Transmission Lubrication
ADC SYSTEM (IF EQUIPPED)
-     ADC System Fluid Reservoir Location
-     ADC Differential Hydraulic Circuit Fluid Change
VEHICLE INSPECTION
-     Shift Link Rod Inspection
-     Throttle Inspection
-     Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
-     Fuel System
-     Fuel Lines
-     Vent Lines
-     Choke (Enricher) Adjustment - (500 Carb)
-     Compression Test
-     Engine Mounts
-     Spark Plug
-     Battery Maintenance
-     Liquid Cooling System Overview
-     Coolant Strength / Type
-     Cooling System Hoses
-     Radiator/Grill Screen
-     Cooling System Pressure Test
-     Coolant Level Inspection

-     Radiator Coolant Level
-     Air Filter/Pre-Filter Service
-     Air Box Sediment Tube
-     Breather Filter Inspection
-     Breather Hose
-     Recoil Housing
-     Engine Oil Level
-     Oil and Filter Change
-     Oil Pump Priming Procedure
-     Valve Clearance
-     Intake Valve Clearance Adjustment
-     Exhaust Valve Clearance Adjustment
-     Steering
-     Tie Rod End/Steering Inspection
-     Camber and Caster
-     Wheel Alignment
-     Toe Alignment Adjustment
-     Exhaust Pipe
-     Brake System Inspection
-     Brake Pad Inspection
-     Hose/Fitting Inspection
-     Auxiliary Brake Testing
-     Auxiliary Brake Adjustment (Hydraulic)
-     Suspension Spring Preload Adjustment
-     Front Suspension
-     CV Shaft Boot Inspection
-     Controls
-     Wheels
-     Wheel, Hub, And Spindle Torque Table
-     Wheel Removal Front or Rear
-     Wheel Installation
-     Tire Pressure
-     Tire Inspection
-     Frame, Nuts, Bolts, Fasteners
CARBURETOR MAINTENANCE
-     Choke (Enricher) Adjustment (Non EFI)
-     Pilot Screw
-     Pilot Screw Adjustment
-     Idle Speed Adjustment (Non EFI)
-     Fuel Filter (Non EFI)
-     Carburetor Draining
-     Maintenance Schedule

CHAPTER 3 - ENGINE

SPECIFICATIONS
-     Torque Specifications
-     Engine Fastener Torque Patterns
-     Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
-     Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
-     Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
-     Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
SPECIAL TOOLS
GENERAL ENGINE SERVICE
-     Cooling System Specifications
-     Cooling System
-     Accessible Components
-     Engine Removal
-     Engine Installation Notes
-     Cylinder Hone Selection/ Honing Procedure
-     Honing To Oversize
-     Cleaning the Cylinder After Honing
-     Crankshaft Straightening
-     Engine Lubrication
-     Oil Pressure Test
-     Oil Flow
-     Oil Flow Diagram
-     Engine Exploded Views
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
-     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 Identification
-     Piston Ring Installed Gap
-     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
-     Oil Pump Priming Procedure
RECOIL (Accessory)
-     Recoil Disassembly/Inspection
-     Recoil Assembly
TROUBLESHOOTING
-     Spark Plug Fouling
-     Engine
-     Cooling System

CHAPTER 4 - FUEL SYSTEMS
CHAPTER 4 - CARBURATION

General Information and Specifications
-     Carburetor Jetting
-     Mikuni Jet Part Numbers
-     Special Tools
Carburetion
-     BST 40 Carburetor Exploded View 1 of 2
-     BST 40 Carburetor Exploded View 2 of 2
-     CV Carburetor System Function
-     Mikuni CV Carb Operation
-     Carburetor Venting
-     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 Disassembly – Mikuni CV
-     Carburetor Cleaning
-     Carburetor Inspection
-     Carburetor Assembly
-     Float Height Adjustment
-     Needle and Seat Leakage Test
-     Fuel Level Test
CARBUTATED Fuel Tank / Fuel Delivery System
-     Fuel System Exploded View
Fuel Pump (CARBURATED)
-     Fuel Filter Replacement (Carbureted)
FUEL GAUGE SENDING UNIT TEST
-     Fuel Sending Unit Test
Fuel PICK-UP / Sending Unit Replacement (CARB.)
-     Fuel Pick-up / Sending Unit Replacement
Fuel Tank Vent Routing (non INTL)
-     Fuel Tank Vent Hose Routing
500 H.O. INTERNATIONAL EMISSIONS SYSTEM
-     Overview
Troubleshooting
-     Fuel Starvation/Lean Mixture
CHAPTER 4 - EFI
SPECIAL TOOLS
-     Part Numbers / Descriptions

500 EFI TRACTOR SPEED CONTROL
-     System Operation Overview
-     Air Control Body Removal and Disassembly
-     Air Control Body Assembly and Installation
-     Air Solenoid Valve Test / Replacement
-     Exhaust System
EFI SERVICE NOTES
-     General Service Information
EFI SYSTEM EXPLODED VIEW
EFI SYSTEM
-     Component Locations/Identification
FUEL SYSTEM AND FUEL TANK
-     Fuel System and Fuel Tank Exploded View
ELECTRONIC FUEL INJECTION
-     General Information
-     EFI Operation Overview
-     Initial Priming / Starting Procedure
FUEL LINES
-     Quick Connect Removal/Installation
ELECTRONIC CONTROL UNIT (ECU)
-     Operation Overview
-     ECU Replacement
-     ECU Service
FUEL PUMP ASSEMBLY
-     Operation / Testing
-     FUEL PUMP TEST
-     Fuel Tank Replacement
-     Fuel Sending Unit Test
-     Fuel Pump Replacement
FUEL PRESSURE REGULATOR
-     General Information
FUEL FILTER
-     General Information
FUEL INJECTOR
-     General Information
CRANKSHAFT POSITION SENSOR (CPS)
-     General Information
MANIFOLD AIR PRESSURE SENSOR (MAP)
-     Operation Overview
-     Map Sensor Test
-     Map Sensor Replacement
INTAKE AIR TEMPERATURE SENSOR (IAT)
-     Operation Overview
-     Intake Air Temperature Sensor Test
-     Intake Air Temperature Sensor Replacement
I DLE AIR CONTROL (IAC)
-     General Information
THROTTLE POSITION SENSOR (TPS)
-     Operation Overview
-     Throttle Position Sensor Test
-     Throttle Position Sensor Replacement
-     Throttle Position Sensor Initialization
ENGINE TEMPERATURE SENSOR
-     General Information
-     Engine Temperature Sensor Test
-     Engine Temperature Sensor Replacement
FUEL SYSTEM TROUBLESHOOTING
-     FUEL STARVATION / LEAN MIXTURE
EFI DIAGNOSTICS USING ‘BLINK CODES’
-     Blink Codes - Operation
DIGITAL WRENCH™ OPERATION
-     Digital Wrench™ Diagnostic Software Overview
-     Special Tools (also refer to page 3.2)
-     Diagnostic Software Version
-     ECU Replacement
-     Guided Diagnostic Available
-     Digital Wrench™ Communication Errors
-     Digital Wrench™ - Diagnostic Connector
-     Digital Wrench™ Version and Update ID
-     Digital Wrench™ Updates
-     Digital Wrench™ Serial Number Location
-     Digital Wrench™ Feature Map
-     Engine Controller Reprogramming (Reflash)
TROUBLESHOOTING DIAGRAMS
-     EFI CIRCUIT - Power On
-     EFI CIRCUIT - Crank Position Sensor
-     EFI CIRCUIT - Fuel Pump
-     EFI CIRCUIT - Ignition Coil
-     EFI CIRCUIT - Idle Air Control
-     EFI CIRCUIT - Throttle Position Sensor
-     EFI CIRCUIT - Manifold Absolute Pressure Sensor
-     EFI CIRCUIT - Engine Coolant Temperature
-     EFI CIRCUIT - Air Temperature Sensor
-     EFI CIRCUIT - Malfunction Indicator Light

CHAPTER 5 - BODY / STEERING / SUSPENSION

GENERAL INFORMATION
-     Torque Specifications
-     Special Tools
-     Decal Replacement
-     Plastic Insert Removal / Installation
BODY
-     Side Panel Removal
-     Front Storage Box Lid / Front Rack and Access Panel Removal / Installation
-     Foot Well Removal / Installation
-     Front Bumper Removal / Installation
-     Mud Guard Removal / Installation
-     Front Fender Removal/Installation
-     Front Rack / Storage Box Lid Assembly
-     Front Cab Assembly
-     Front Bumper Assembly
-     Rear Rack Assembly
-     Rear Cab And Seat Assembly
-     Rear Storage Box Assembly
-     Winch and Front Bumper Mounting
-     Headlight Pod Exploded View
500 EFI TRACTOR SEAT ASSEMBLY
-     Overview
-     Seat Dampener Repair
-     Seat Pivot Repair
-     500 EFI Tractor Seat Assembly Exploded View
500 EFI TRACTOR STEERING POST AND LOCK
-     Steering Assembly Exploded View
STEERING
-     Handlebar Block Installation Procedure
-     Steering / A-arm Exploded View
-     A-Arm Replacement
-     Ball Joint Replacement
-     Steering Post Removal
-     Steering Post Assembly
SUSPENSION
-     Front Strut Cartridge Replacement
-     Strut Assembly
-     Sportsman Rear Suspension Assembly
-     Torsion Bar Exploded View

CHAPTER 6 - CLUTCHING

SPECIAL TOOL and SUPPLIES
TORQUE SPECIFICATIONS
-     PVT System Fastener Torques
PVT SYSTEM OVERVIEW
-     General Operation
-     Drive Clutch Operation
-     Driven Clutch Operation
-     PVT Break-In (Drive Belt / Clutches)
-     Maintenance / Inspection
-     Clutching Chart
-     Overheating / Diagnosis
PVT EXPLODED VIEWS
-     PVT Sealing And Ducting Components
-     Drive Clutch Exploded Views (EBS vs. Non-EBS)
PVT SYSTEM SERVICE
-     Disassembly
-     Assembly
DRIVE BELT
-     Belt Removal
-     Belt Inspection
-     Belt Installation
-     PVT Break-In (Drive Belt / Clutches)
CLUTCH ALIGNMENT
-     Clutch Alignment Tool Use
-     Belt Deflection (Tension)
CLUTCH CENTER DISTANCE
-     Setting Center-To-Center Distance
DRIVE CLUTCH SERVICE (non EBS)
-     Exploded View (NON EBS)
-     Clutch Disassembly
-     Drive Clutch Spring Inspection
-     Shift Weight Inspection
-     Spider Removal
-     Button To Tower Clearance Inspection
-     Shift Weight Inspection
-     Bearing Inspection
-     Clutch Inspection
-     Moveable Sheave Bushing Inspection
-     Clutch Assembly
EBS DRIVE CLUTCH SERVICE
-     EBS Drive Clutch Exploded View
-     Drive Clutch Disassembly
-     Spider Removal
-     Button To Tower Clearance Inspection
-     Shift Weight Inspection
-     Drive Clutch Inspection
-     Moveable Sheave Bushing Inspection
-     One-Way Clutch Inspection (EBS Drive Clutch)
-     Drive Clutch Reassembly
DRIVE CLUTCH BUSHING SERVICE (NON EBS and EBS)
-     Bushing Service
DRIVEN CLUTCH SERVICE (NON EBS)
-     Exploded View (NON EBS)
-     Clutch Disassembly / Inspection
-     Clutch Assembly
DRIVEN CLUTCH SERVICE (EBS)
-     Driven Clutch Exploded Views (EBS)
-     Clutch Disassembly
-     Clutch Assembly
Driven Clutch Bushing service
-     Driven Clutch Bushing Service (NON EBS and EBS)
TROUBLESHOOTING

CHAPTER 7 - FINAL DRIVE

SPECIFICATIONS
-     Torque Table
-     Special Tools
-     Gearcase Fluid / Capacity
FRONT HUB
-     Disassembly
-     Assembly
FRONT GEARCASE REMOVAL AND INSTALLIATION (ADC AND NON ADC)
-     Gearcase Removal
-     Gearcase Installation
FRONT GEARCASE - CENTRALIZED HILLIARD NON ADC (4x4)
-     Operation NON ADC
-     Disassembly / Inspection NON ADC
-     Reassembly / Inspection NON ADC
-     Front Gearcase Diagnosis
-     Setting Ring Gear Backlash NON ADC
FRONT GEARCASE - CENTRALIZED HILLIARD ADC
-     Operation
-     ADC Gearcase Exploded View
-     ADC Operation
-     Front Gearcase Diagnosis
-     Coil Testing
-     ADC Differential Hydraulic Circuit Bleeding
-     Disassembly / Inspection
-     ADC Gearcase Piston Replacement Procedure
-     Assembly
-     Setting Ring Gear Backlash
FRONT DRIVE (CV) SHAFT
-     Inspection
-     Removal
-     Installation
REAR HUB
-     Removal
-     Disassembly
-     Assembly
-     Installation
REAR DRIVE (CV) SHAFT
-     Inspection
-     Removal
-     Installation
CV DRIVE SHAFT SERVICE
-     Drive Shafts and Propshafts Components
-     Drive Shaft and CV Joint Handling Tips
-     Outer CV Joint / Boot Replacement
-     Inner Plunging Joint / Boot Replacement
-     Drive Shaft Exploded Views
PROP SHAFT - FRONT OR REAR
-     Removal and Installation
U-JOINT SERVICE
-     Disassembly
-     Assembly

CHAPTER 8 - TRANSMISSION

TRANSMISSION - GENERAL
-     Torque Specifications
-     Special Tools
-     Lubrication
-     Transmission Frame Mounts
-     Transmission Upper Frame Mount
-     Transmission Rear Stabilizer Mounts
-     Transmission Control Arm Bracket Mounts
-     Shift Linkage Inspection
-     Gear Selector Removal
-     Transmission Removal
-     Transmission Installation
-     Troubleshooting Checklist
2012 SPORTSMAN TRANSMISSION EXPLODED VIEW
-     2012 Sportsman Transmission Exploded View
tRANSMISSION dISASSEMBLY / aSSEMBLY
-     Transmission Disassembly
-     Snorkel / Output Gear Backlash Procedure
-     Transmission Assembly

CHAPTER 9 - BRAKES

SPECIFICATIONS
-     Torque Table
-     Component Service Limits
SPECIAL TOOLS
-     Special Tools
HYDRAULIC BRAKE SYSTEM
-     Operation Overview
-     Overview: Sportsman Forest 500 (INTL A12MH50FF)
-     Brake Noise Troubleshooting
-     Brake Bleeding / Fluid Change
BRAKE SYSTEM Exploded Views
-     Sportsman Touring 500 HO Component Exploded View
-     Sportsman 400 HO, 500 HO and International Forest Component Exploded View
-     Sportsman Forest Tractor 500 (INTL A12MH50FF) Component Exploded View
BRAKE CALIPER EXPLODED VIEWS
-     Sportsman 400 HO, 500 HO, Touring and Forest 500 (INTL.) Front Caliper Assembly
-     Sportsman 500 HO Touring Rear Caliper Assembly (non INTL.)
-     400, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.) Rear Caliper Assembly
-     Sportsman Forest 500 (INTL.) Front Caliper Assembly
FRONT MASTER CYLINDER All Models
-     Removal
-     Installation
FRONT BRAKES
-     Pad Removal
-     Assembly
-     Brake Burnishing Procedure
FRONT BRAKE DISC
-     Inspection
-     Removal / Replacement
FRONT CALIPER
-     Removal
-     Inspection
-     Reassembly
-     Installation
REAR BRAKE PAD
-     Touring Pad Removal
-     Touring Pad Installation
-     Sportsman Rear Pad Removal
-     Sportsman Rear Pad Installation
-     Brake Burnishing Procedure
TOURING REAR CALIPER
-     Removal
-     Inspection
-     Reassembly
Sportsman REAR CALIPER
-     Removal and Inspection
-     Assembly
REAR BRAKE DISC
-     Inspection
REAR MASTER CYLINDER
-     Sportsman 500 HO Touring Exploded View (Non Intl)
-     Sportsman 400 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.)
-     Overview
-     Touring Rear Master Cylinder Removal and Installation
-     Sportsman Rear Master Cylinder Removal / Installation
-     Pedal Removal and Installation
TROUBLESHOOTING
-     Brakes Squeal
-     Poor Brake Performance
-     Lever Vibration
-     Caliper Overheats (Brakes Drag)
-     Brakes Lock

CHAPTER 10 - ELECTRICAL

GENERAL INFORMATION
-     Special Tools
-     Ignition System / Basic Electrical Components
-     Electrical Service Notes
-     Troubleshooting
INSTRUMENT CLUSTER
-     Overview
-     Instrument Cluster Diagnostic Mode
-     Setting A New Service Interval
-     EFI Diagnostic Mode
-     Speedometer Removal
-     Speedometer Installation
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
-     TEST 1 - No All Wheel Drive
-     TEST 2 - No Speedometer Display
-     TEST 3 - No Reverse Speed Limit
-     TEST 4 - No AWD Hub Safety Limit
-     TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor
-     TEST 6 - Vehicle Speed Sensor
-     Speed Sensor Location
-     Speed Sensor Testing
-     TEST 7 - Fuel Gauge Display Not Working
-     TEST 8 - Shift Indicator Not Working
ALL WHEEL DRIVE (AWD) COIL
-     Operation Overview
-     Diagnosing System Failures
COOLING SYSTEM COMPONENTS
-     Fan Control Circuit Operation
-     Fan Control Bypass Test - EFI
-     Fan Control Bypass Test - H.O.
-     Fan Motor Current Draw Test
-     Coolant Temperature Sensor - EFI
-     Coolant Temperature Fan Switch - H.O.
GEAR POSITION INDICATOR SWITCH
-     Test Diagram
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
-     Operation Overview
-     ETC Test
IGNITION SYSTEM
-     Overview
-     Components of Alternator and DC / CDI Ignition System
-     EFI Ignition System Testing Flow Chart
-     Crankshaft Position Sensor Gap
-     Ignition Troubleshooting
-     Ignition Output Test Using Gap Tester
CHARGING SYSTEM
-     Current Draw - Key Off
-     Break Even Test
-     Alternator Output Test
-     Charging System Testing Diagrams
RELAYS
-     Operation
FUSES/Circuit Breaker
-     Operation
LIGHTING
-     High Beam Headlight Bulb Replacement
-     Headlight Housing Replacement
-     High Beam Headlight Adjustment
-     Lower Headlamp Removal / Installation
-     Low Beam Headlight Adjustment (Non Intl)
-     Lower Headlight Adjustment (Forest Tractor)
-     Headlamp Switch Test
-     Brake Light Replacement
-     Brake Light Switch
SPEED SENSOR
-     Testing
-     Replacement
FUEL SENDER
-     Testing
-     ACCESSORY POWER
-     Wire Connections
STARTER SYSTEM
-     Troubleshooting
-     VOLTAGE DROP TEST
-     Starter Lockout Troubleshooting- EFI
-     Starter Lockout Troubleshooting- H.O.
-     Starter Lockout Diagram- EFI
-     Starter Lockout Diagram- Carb
-     Starter Motor Removal / Disassembly
-     Brush Inspection / Replacement
-     Armature Testing
-     Starter Reassembly
-     Starter Solenoid Bench Test
-     Starter Exploded View
STARTER DRIVE
-     Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
STARTER SYSTEM TESTING FLOW CHART
-     Condition: Starter fails to turn motor.  
BATTERY
-     Battery Identification
-     Battery Conductance Analyzer
-     Battery Activation (Conventional)
-     Battery Terminals/Bolts
-     Conventional Battery Inspection / Removal
-     Conventional Battery Installation
-     Conventional Battery Testing
-     Conventional Battery OCV - Open Circuit Voltage Test
-     Conventional Battery Specific Gravity Test
-     Battery Load Test
-     Off Season Storage
-     Charging Procedure
-     Low Maintenance Battery
-     Low Maintenance Battery Charging
-     Low Maintenance Battery Inspection / Removal
-     Low Maintenance Battery Installation
-     Low Maintenance Battery - OCV- Open Circuit Voltage Test
-     Low Maintenance Battery Load Test
-     Low Maintenance Battery Charging Procedure
-     Low Maintenance Battery Off-season Storage
TROUBLESHOOTING DIAGRAMS
-     All Wheel Drive - EFI
-     Fuel Pump - EFI
-     Fan Control - EFI
SPORTSMAN 500 EFI Forest TRACTOR ELECTRICAL
-     Head Lamps / Tail Lamps - Exploded View
-     Hazard / Flasher Module
-     Rear Tail Lamp / Turn Signal Lamp Replacement
-     Front Turn Signal Lamp Replacement
-     Pod Indicator Lamp / Switch Replacement
-     Trailer Connector and Fuses
-     Speed Control Diagram

WIRING DIAGRAMS