2005 - Polaris Sportsman 400/500 Service Manual
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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Reviews - Write a Review
Rated: 5 by: Jason Posted: Friday, May 11, 2012 at 12:43PM
Rated: 5 by: Mike Posted: Tuesday, October 29, 2013 at 10:55AM
Rated: 4 by: Dave Dickerson Posted: Saturday, November 4, 2023 at 3:59PM
I haven't been through the manual enough to rate it completely but from what I've seen so far looks good!
Thanks
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