I have a Clymer's Sportsman 400/500 service manual 1996-2003 and found some weird advice or misprints here and there inside of it.
They say use 10w-30 motor Oil,when it should be 0w-40.

Clymer said to Take both clutch pulleys and back plate to just remove a starter, when removing the air box is 100% easier.

I just change my rear inner CV boot, but my manuals input on it states:

" Rubber boot replacement requires disassembly or the rear axle,and cv must be cleaned and repacked therefore refer this service to a Polaris Dealer."

That one was the worst.

It also said take off the whole front Plastic and bumper to change a rad fan! I did it in 30 min through the hood hatch were the the rad cap is and under the fenders.

I wounder if these guys even really work on a ATV.

 

Kinda makes you wonder if some of the shops charging 70+ bucks an hour for labor are using those type manuals.

 

Another reason why I bought the Factory Polaris Service Manual. However did not seem to find any major errors in it. Not much repairs to do yet either.
...Caper.......

 

Look it up Caper on your Polaris manual,if they say remove both clutches two remove a starter and have a dealer replace a rear CV boot. I,m just curious.

thanks,

 

I will go to the garage and get my manual now.
....Caper.....

 

[QUOTE=TLC;2941452]Look it up Caper on your Polaris manual,if they say remove both clutches two remove a starter and have a dealer replace a rear CV boot. I,m just curious.

thanks,
No does not say that........Remember this is a dealer service manual so for the C.V. boot it will not tell you to have a dealer replace it.
As for the starter there are many topics covered ,including Polaris replacement brush kit number and how to actually take apart the starter to re-build......
This factory manual is the way to go,lots of pictures and info,Even give me a polaris part number for the starter grease(PN 2871460).....LOL...LOL....
...Caper......

 

I should of bought that manual but I heard they were like $100.

 

I got mine from the dealer in Bancroft back in 2006 for around $65.00 Canadian.
I have two 2006 Sp 450's so I thought the manual will come in handy.

Part number of the manual is 9920008

Covers 2005 Sportsman 400/500
and.....2006 Sportsman 450/500

 

MY "Clymer" was $45 from Canadian Tire. EEKS.

 

I got my factory manual on ebay for about 25 shipped.

For the motorcycle, the person I bought it from had both a factory and clymers. Kinda nice to have the two to compare, but never really paid any attention to the instructions in the clymers unless it wasn't in the factory one. Now I'll have to look at them closer.