Polaris Sportsman 400 500 (2005) - Service Manual - Wiring Diagram - Parts Catalogue

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POLARIS 400 & 500 SPORTSMAN (2005) - WORKSHOP, SERVICE, REPAIR MANUAL - PARTS

- English Service Manual, Wiring Diagram and  Parts Catalogue to ATVs Polaris Sportsman 400 500 (2005).


CONTENTS:


SERVICE MANUAL 400-500

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

PARTS MANUAL 400

PARTS MANUAL 500