Polaris Sportsman 2001 Service

Polaris Sportsman · 2001 · service manual · 381 pages

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Spark plug threads19 N·m14 ft·lbp. 48
Front Wheel Nuts27.1 N·m20 ft·lbp. 67
Rear Wheel Nuts27.1 N·m20 ft·lbp. 67
Rear Hub Retaining Nut135.6 N·m100 ft·lbp. 67
Drain Plug / Screen Fitting19 N·m19 N·mp. 82
Front A-Arm Attaching Bolt40.7 N·m41 N·mp. 172
Front A-Arm Ball Joint Stud Nut33.9 N·m35 N·mp. 172
Rear Shock Bolt40.7 N·m41 N·mp. 172
Rear Wheel Hub Nut135.6 N·m136 N·mp. 172
Upper Stabilizer Support Nut23 N·m24 N·mp. 172
Upper Control Arm Mounting Bolt47.5 N·m48 N·mp. 172
Lower Control Arm Mounting Bolt40.7 N·m41 N·mp. 172
Upper Wheel Bearing Carrier Bolt47.5 N·m48 N·mp. 172
Lower Wheel Bearing Carrier Bolt40.7 N·m41 N·mp. 172
Strut Rod Retaining Nut20.3 N·m21 N·mp. 172
Strut Casting Pinch Bolt20.3 N·m21 N·mp. 172
Vehicle Frame Bolt40.7 N·m30 ft·lbp. 178
A-Arm Shaft10.8 N·m8 ft·lbp. 178
Washer A-Arm Tube35 N·mp. 178
CV Joint Shield Cotter Pin40.7 N·m41.4 N·mp. 178
Clamp24.4 N·m18 ft·lbp. 180
Clamp25 N·mp. 180
Drive Clutch Retaining Bolt54.2 N·m40 ft·lbp. 185
Driven Clutch Retaining Bolt23 N·m17 ft·lbp. 185
PVT Inner Cover Bolts16.3 N·m12 ft·lbp. 185
Drive Clutch Spider271.2 N·m200 ft·lbp. 185
EBS Clutch250.8 N·m185 ft·lbp. 185
Drive Clutch Spider Limiter Nut6.8 N·m5 ft·lbp. 185
Drive Clutch Cover Plate10.2 N·m90 in·lbp. 185
Cover bolts evenly271.2 N·m276 N·mp. 202
Bushing250.8 N·m185 ft·lbp. 220
Roll pin33.9 N·m34.5 N·mp. 244
Spindle and axle assembly35 N·mp. 248
Pinion Shaft Lock Nut88.1 N·m89.7 N·mp. 256
O-ring and bolts19 N·m14 ft·lbp. 256
Cover Bolts19 N·m14 ft·lbp. 256
Rear Wheel Nut27.1 N·m27 N·mp. 261
Transmission Case Bolts16.3 N·m16.6 N·mp. 270
Bell Crank Nut16.3 N·m16.6 N·mp. 270
Transmission Drain Plug19 N·m19.3 N·mp. 270
Transmission Mounting Bolts33.9 N·m34.5 N·mp. 270
Cover screws16.3 N·m1.7 kgf·mp. 273
Rear Wheel Retaining Bolt27.1 N·m27 N·mp. 279
Reservoir Cover5.1 N·m5 N·mp. 311
Mounting bolts6.2 N·m6 N·mp. 316
Purge master cylinder of air21 N·mp. 316
Master Cylinder Mounting Bolt6.2 N·m6 N·mp. 316
Brake Line Banjo Bolt20.3 N·m21 N·mp. 316
Front Caliper Mounting Bolts24.4 N·m25 N·mp. 318
Front Wheel Nut27.1 N·m27 N·mp. 319
Front Brake Disc Mounting Bolt24.4 N·m25 N·mp. 320
Front Caliper Mounting Bolt24.4 N·m25 N·mp. 324
DH Brake Caliper24.4 N·m24.9 N·mp. 327
Body screw24.4 N·m18 ft·lbp. 329
Caliper Body24.4 N·m25 N·mp. 329

Spark plugs

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
FF95—p. 14
FF97—p. 16
EH42PL—p. 69

Service intervals

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Coolant change2 yearsp. 29
Brake inspection2 yearsp. 33
Air filter service1 yearsp. 51

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