Polaris Sportsman 400 / 500 Repair Service Manual 2005

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This workshop repair service manual PDF download for the 2005 Polaris Sportsman 400 / 500 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2005 SPORTSMAN 400
MODEL NUMBER: A05MH42AB, AG, AH
ENGINE MODEL: EH42PLE

MODEL: 2005 SPORTSMAN 500
MODEL NUMBER: A05MH50AB, AC, AG, AH
ENGINE MODEL: EH50PLE

TABLE OF CONTENTS :

CHAPTER 1-GENERAL
CHAPTER 2-MAINTENANCE
CHAPTER 3-ENGINE
CHAPTER 4-FUEL/CARBURETION
CHAPTER 5-BODY AND STEERING
CHAPTER 6-CLUTCHING
CHAPTER 7-FINAL DRIVE
CHAPTER 8-TRANSMISSION
CHAPTER 9-BRAKES
CHAPTER 10-ELECTRICAL
WIRING DIAGRAMS
INDEX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9919425
Total Pages : 312

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

INTRODUCTION
TABLE OF CONTENTS
CHAPTER 1-GENERAL
MODEL IDENTIFICATION
SERIAL NUMBER LOCATION
PUBLICATION NUMBERS
PAINT CODES
REPLACEMENT KEYS
GENERAL SPECIFACTIONS -SPORTSMAN 400/500
SPECIAL TOOLS
STANDARD TORQUE SPECIFICATIONS
DECIMAL EQUIVALENT CHART
COVERSION TABLE
GLOSSARY OF TERMS
CHAPTER 2-MAINTENANCE
PERIODIC MAINTENANCE CHART
LUBRICANT AND MAINTENANCE PRODUCT NUMBERS
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
WARN™ WINCH OPERATION
CLEANING AND STORAGE OF ATV
CHAPTER 3-ENGINE
TORUE SPECIFICATIONS
SPECIAL TOOLS
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
SPARK PLUG FOULING CHECKLIST
TROUBLESHOOTING
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
CARBURETOR JETTING
MAIN JET/PILOT JET PART NUMBERS
CV CARBURETOR SYSTEM FUNCTION (4 CYCLE)
CV CARBURETOR VENT SYSTEM (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
AWD FRONT DRIVE AXLE EXPLODED VIEW
FRONT HUB DISASS./ASSEMBLE
AWD FRONT PROP SHAFT REMOVAL
U-JOINT DISASSEMBLE/ASSEMBLE
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
A-C
C-E
E-G
G-P
P-T
T-W

 

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Polaris Sportsman 400 / 500 Repair Service Manual 2005.pdf

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