Atv Polaris 2005 - Polaris Sportsman 400-500 Service Manual
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Original 2005 Polaris Sportsman 400-500 Service Manual.
Manual chapters:
CHAPTER 1-GENERAL
- MODEL IDENTIFICATION
- SERIAL NUMBER LOCATION
- PUBLICATION NUMBERS
- PAINT CODES
- REPLACEMENT KEYS
- GENERAL SPECIFACTIONS -SPORTSMAN 400/500
- STANDARD TORQUE SPECIFICATIONS
CHAPTER 2-MAINTENANCE
- PERIODIC MAINTENANCE CHART
- ATV COMPONENT LOCATIONS
- LUBRICATION CHARTS
- FRONT GEARCASE LUBRICATION
- TRANSMISSION LUBRICATION
- LUBRICATIONS POINTS
- TRANSMISSION LINKAGE AJUSTMENTS
- CARBURETOR/THROTTLE ADJUSTMENTS
- FUEL SYSTEM
- COMPRESSION TEST
- BATTERY MAINTENANCE
- COOLANT SYSTEM MAINTENANCE
- AIR FILTER SERVICE
- AIR BOX SEDIMENT TUBE SERVICE
- BREATHER FILTER
- RECOIL HOUSING
- OIL CHANGE/FILTER
- VALVE CLEARANCE
- STEERING AND TOE ALIGNMENT
- EXHAUST SYSTEM MAINTENANCE
- BRAKE SYSTEM SERVICE
- SUSPENSION SERVICE
- CONTROLS
- WHEEL REMOVAL/INSTALATION
- TIRE INSPECTION
- COMPARTMENT STORAGE
- CLEANING AND STORAGE OF ATV
CHAPTER 3-ENGINE
- EH50PL SERVICE DATA
- TORQUE PATTERNS
- PISTON IDENTIFICATION
- COOLING SYSTEM PRESSURE TEST
- COOLING SYSTEM SPECIFICATIONS
- ENGINE REMOVAL
- ENGINE INSTALLATION NOTES
- CYLINDER HONEING
- CRANKSHAFT RUNOUT INSPECTION
- EH50PL ENGINE LUBRICATION
- EH50PL OIL PUMP PRIMING PROCEDURE
- EH50PL LUBRICATION/OIL FLOW
- EH50PL ENGINE EXPLODED VIEW
- EH50PL ENGINE TOP END DISASSEMBLY
- EH50PL VALVE SEAT SERVICE
- EH50PL CYLINDER HEAD ASSEMBLY
- EH50PL ENGINE BOTTOM END DISASSEMBLY
- EH50PL CRANKCASE & BEARING ASSEMBLY
- EH50PL CRANKSHAFT END PLAY INSPECTION
- EH50PL COUNTER BALANCER SHAFT END PLAY INSPECTION
- EH50PL OIL PUMP SHAFT END PLAY INSPECTION
- EH50PL ENGINE ASSEMBLY/INSPECTION
- SEALED RECOIL DISASSEMBLY/INSPECTION
- SEALED RECOIL ASSEMBLY
CHAPTER 4-FUEL/CARBURETION
- EXPLODED VIEW, MIKUNI BST 34/40 CARBURETOR
- FUEL TANK ASM. EXPLODED VEIW
- FUEL FLOW DIAGRAM
- FUEL COMPONENT OVERVIEW
- FUEL SENDER REMOVAL/INSTALL
- SPECIAL TOOL & JETTING GUIDELINES
- CV CARBURETOR VENT SYSTEM (4 CYCLE)
- CARBURETOR JETTING
- MAIN JET/PILOT JET PART NUMBERS
- CV CARBURETOR SYSTEM FUNCTION (4 CYCLE)
- CV CARBURETOR OPERATION
- PILOT SCREW INFORMATION
- DISASSEMBLY NOTES, CV CARBURETOR
- CLEANING, CV CARBURETOR
- INSPECTION, CV CARBURETOR
- ASSEMBLY, CV CARBURETOR
- FLOAT ADJUSTMENT, CV CARBURETOR
- NEEDLE & SEAT LEAKAGE TEST
- FUEL LEVEL
- FUEL PUMP SERVICE
- TROUBLESHOOTING
CHAPTER 5-BODY AND STEERING
- TORQUE SPECIFICATIONS AND SPECIAL TOOLS
- PLASTIC INSERT REMOVAL/INSTALL
- SIDE PANEL REMOVAL
- FRONT COVER REMOVAL
- FOOT WELL REMOVAL/INSTALL
- FRONT STORAGE REMOVAL/INSTALL
- REAR RACK REMOVE/INSTALL
- FRONT CAB / FENDER REMOVE/INSTALL
- REAR CAB / FENDER REMOVE/INSTALL
- RADIATOR SCREEN REMOVAL
- BODY ASSEMBLY, EXPLODED VIEW
- HEADLIGHT POD, EXPLODED VIEW
- HANDLEBAR BLOCK INSTALLATION
- STEERING ASSEMBLY, EXPLODED VIEW
- A-ARM REPLACEMENT
- REAR SUSPENSION ASSEMBLY
- STRUT ASSEMBLY EXPLODED VIEW
- FRONT STRUT CARTRIDGE REPLACEMENT
- FRONT STRUT BALL JOINT REPLACEMENT
- STEERING POST ASSEMBLY
- DECAL REPLACEMENT
CHAPTER 6-CLUTCHING
- SPECIAL TOOLS, SUPPLIES & TORQUES
- PVT SYSTEM OPERATION
- PVT MAINTENANCE/INSPECTION
- PVT DISASSEMBLY
- PVT ASSEMBLY
- PVT SEALING AND DUCTING COMPONENTS
- DRIVE CLUTCH EXPLODED VIEW
- DRIVE CLUTCH SPRING SPECIFICATIONS
- SHIFT WEIGHTS
- DRIVE CLUTCH INSPECTION
- DRIVE CLUTCH DISASSEMBLY
- DRIVE CLUTCH ASSEMBLY
- DRIVE BELT TENSION
- DRIVE BELT REMOVAL/INSPECTION
- DRIVE BELT INSTALLATION
- CLUTCH ALIGNMENT/OFFSET
- DRIVE CLUTCH BUSHING SERVICE
- DRIVEN CLUTCH DISASSEMBLY/INSPECTION
- DRIVEN CLUTCH ASSEMBLY
- DRIVEN CLUTCH BUSHING SERVICE
- EBS EXPLODED VIEW
- EBS DRIVE CLUTCH DISASSEMBLY/INSPECTION
- EBS DRIVE CLUTCH BUSHING SERVICE
- EBS DRIVEN CLUTCH DISASS./INSP.
- EBS DRIVEN CLUTCH BUSHING SERV.
- TROUBLESHOOTING
CHAPTER 7-FINAL DRIVE
- FINAL DRIVE TORQUE SPECIFICATIONS
- AWD FRONT AXLE REMOVE/INSTALL
- AWD FRONT CV JOINT BOOT REPLACE
- FRONT HUB DISASS./ASSEMBLE
- AWD FRONT PROP SHAFT REMOVAL
- U-JOINT DISASSEMBLE/ASSEMBLE
- AWD FRONT DRIVE AXLE EXPLODED VIEW
- DRIVE AXLE / PROPSHAFT EXPLODED VIEW
- AWD FRONT GEARCASE OPERATION
- AWD FRONT GEARCASE SERVICE
- REAR HUB REMOVE/INSTALL
- REAR HUB DISASSEMBLY/ASSEMBLY
- REAR DRIVE SHAFT REMOVAL
- DRIVESHAFT / CV JOINT TIPS
- REAR DRIVESHAFT INSTALLATION
- REAR DRIVESHAFT SERVICE
CHAPTER 8-TRANSMISSION
- TRANSMISSION MOUNTING
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- TRANSMISSION REMOVAL
- TRANSMISSION INSTALLATION
- TRANSMISSION DISASSEMBLY
- TRANSMISSION ASSEMBLY
- TROUBLESHOOTING
- TRANSMISSION EXPLODED VIEW
CHAPTER 9-BRAKES
- SPECIAL TOOLS/SPECIFICATIONS/TORQUES
- BRAKE SYSTEM COMPONENTS
- REAR CALIPER EXPLODED VIEW
- FRONT CALIPER EXPLODED VIEW
- REAR AUXILIARY MASTER CYLINDER EXPLODED VIEW
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OVERVIEW
- HYDRAULIC CALIPER BLEEDING
- BRAKE BLEEDING / FLUID CHANGE
- MASTER CYLINDER REMOVAL
- MASTER CYLINDER INSTALLATION
- FRONT PAD REMOVAL
- FRONT PAD ASSEMBLY
- BRAKE BURNISHING
- FRONT DISC INSPECTION
- FRONT DISC REMOVAL/REPLACEMENT
- FRONT CALIPER REMOVAL
- FRONT CALIPER DISASSEMBLY
- FRONT CALIPER INSPECTION
- FRONT CALIPER REASSEMBLY
- FRONT CALIPER INSTALLATION
- REAR PAD REMOVAL
- REAR PAD INSTALLATION
- REAR CALIPER REMOVAL/INSPECTION
- REAR CALIPER REASSEMBLY
- REAR DISC INSPECTION
- REAR (AUXILIARY) BRAKE REMOVE/INSTALL
- TROUBLESHOOTING
CHAPTER 10-ELECTRICAL
- SPECIAL TOOLS/SERVICE NOTES
- GEAR POSITION SWITCH TEST
- ECM OPERATION
- ELECTRICAL COMPONENTS
- INSTRUMENT CLUSTER OPERATION
- SPEEDOMETER REMOVAL/INSTALLATION
- SPEEDOMETER TROUBLESHOOTING
- COOLANT SENSOR TESTS
- FAN MOTOR TESTS
- ELECTRONIC THROTTLE CIRCUIT SYSTEM OPERATION
- IGNITION SYSTEM INFORMATION
- IGNITION SYSTEM TESTING FLOW CHART
- IGNITION SYSTEM TROUBLESHOOTING
- CDI OUTPUT TESTS
- CHARGING SYSTEM TESTING
- TIMING CHECK PROCEDURE
- BATTERY ACTIVATION/SERVICE
- HEAD LIGHT/BRAKE LIGHT LAMP SERVICE
- FUEL SENDER TEST
- ACCESSORY WIRE HOOKUP
- WARN™ WINCH WIRING SCHEMATIC
- STARTER SYSTEM TROUBLESHOOTING
- STARTER MOTOR SERVICE
- STARTER DRIVE
- STARTER ASSEMBLY EXPLODED VIEW
- STARTER SYSTEM TESTING FLOW CHART
WIRING DIAGRAMS
INDEX
Manual covers all aspects of repair and servicing 2005 Polaris Sportsman 400-500 ATVs, it includes wiring diagrams specifications.
Atv Polaris 2005 - Polaris Sportsman 400-500 Service Manual
Manual has 309 pages.
File size 50.31Mb.
DOWNLOAD Polaris 2005 - Polaris Sportsman 400-500 Service Manual - Back to all "ATV"
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