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.

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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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