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.

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Full list of manual chapters:

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 and 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 and 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 and 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 and 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