Polaris 400 / 500 Sportsman (2005) - Workshop Manual - Wiring Diagram

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

- English Workshop Manual, Wiring Diagram and Owners Manual to ATVs Polaris 400 & 500 Sportsman (2005).

CONTENTS:

WORKSHOP 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