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2005 SPORTSMAN 400
Polaris 2005 SPORTSMAN 400 User Manual
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
SPORTSMAN 400/500
6(5
9,&(0$18$/
31
99194
31
25
3ULQWHGLQ86$
2005 SPORTSMAN 400/500
6(5
9,&(0$18$/
31
25
31
9919425

SPORTSMAN 400/500
6(5
9,&(0$18$/
31
99194
31
9919425
Cvr_9919425 7/28/04 10:19 AM Page 1
2
Table of Contents
General Maintenance
5
Table of Contents
5
Model Identification
6
Serial Number Location
6
Publication Numbers
7
Replacement Keys
7
General Information Special Tools
11
Special Tools
11
Standard Torque Specifications
17
Conversion Table
19
Glossary of Terms
20
Maintenance
21
Periodic Maintenance Chart
22
Maintenance and Lubrication
23
Polaris Lubricant Symbol Identification
26
Front Gearcase Lubrication
30
Transmission Lubrication
31
Lubrications Points
32
Throttle Inspection
33
Pilot Screw Adjustment
35
Idle Speed Adjustment
35
Throttle Cable
36
Fuel System
36
Fuel Lines
36
Vent Lines
37
Carburetor Draining
37
Compression Test
38
Spark Plug
38
Engine Mounts
38
Battery Maintenance
39
Liquid Cooling System
39
Cooling System Pressure Test
40
Cooling System Hoses
40
Coolant Level
40
Radiator Coolant Level
41
Air Box Sediment Tube Service
42
Breather Filter
43
Recoil Housing
43
Engine Oil Level
44
Oil and Filter Change
44
Oil Pump Priming
46
Valve Clearance
46
Camber and Caster
49
Wheel Alignment
49
Toe Alignment
49
Exhaust Pipe
50
Brake System Inspection
51
Brake Pad Inspection
51
Auxiliary Brake Testing
52
Suspension Spring Preload Adjustment
52
Controls
53
Front Suspension
53
Torque Table
53
Tire Inspection
54
Wheel Removal/Installation
54
Tire Pressure
54
Warnt Winch Operation
56
Maintenance Schedule
60
Maintenance Maintenance Schedule
61
Special Tools
62
Torque Specifications
62
Engine Service Data
63
Cooling System Specifications
65
Piston Identification
65
Torque Patterns
65
Engine Removal
67
Water Pump Mechanical Seal Puller
67
Engine Installation Notes
68
Cleaning the Cylinder after Honing
69
Crankshaft Straightening
69
Honing to Oversize
69
Engine Lubrication
70
Oil Pressure Test
70
Eh50Pl Oil Flow Diagram
72
EH50PL Engine Exploded View
73
Automatic Compression Release Installation
78
Camshaft Inspection
78
Cylinder Head Disassembly
81
Cylinder Head Warpage
81
Valve Inspection
82
Cylinder Head Assembly
86
Valve Sealing Test
86
Piston Support Block
88
Cylinder Inspection
89
Crankcase Disassembly
91
Flywheel Puller
92
Crankcase Separation
93
One Way Valve
93
Oil Pump
94
Oil Pump Assembly
95
Crankcase Bearing
97
Crankcase Inspection
97
Bearing Installation
98
Crankcase Assembly
101
Water Pump Mechanical Seal Installation
102
Water Pump Install Kit
103
Piston Installation
104
Piston Ring Installation
104
Cylinder Installation
105
Thermostat Installation
110
Oil Pipes
111
Recoil Assembly
112
Spark Plug Fouling Checklist
113
Troubleshooting
113
Cooling System
114
Fuel System/Carburetion
115
Fuel Flow Diagram
118
Fuel Component Overview
119
Fuel Sender Remove/Install
119
Carburetor Float Adjustment Tool
120
Carburetor Jetting
121
CV Carburetor System Function (4 Cycle)
121
Mikuni Jet Part Numbers
121
Assembly, CV Carburetor
122
CV Carburetor Operation
122
Float System
123
Main System
124
Carburetor Cleaning
126
Carburetor Inspection
126
Carburetor Assembly
127
Fuel Level
129
Fuel Pump
129
Needle & Seat Leakage Test
129
Fuel Pump Disassembly
130
Troubleshooting
131
Table of Contents
133
Plastic Insert Removal/Install
134
Ball Joint Replacement Tool
134
Side Panel Removal
135
Foot Well Removal/Install
136
Front Cover Removal
136
Front Storage Removal/Install
137
Front Storage Installation
139
Radiator Screen Removal
142
Body Assembly Exploded View
143
Body Rack Exploded View
144
Headlight Pod Exploded View
145
Handlebar Block Installation Procedure
146
A-Arm Replacement
148
Rear Suspension Assembly
149
Strut Assembly
150
Front Strut Cartridge Replacement
151
Ball Joint Replacement
151
Decal Replacement
152
Clutch Puller
154
Pvt Drying
155
Pvt Disassembly
157
Pvt Sealing and Ducting Components
159
Drive Clutch Spring Specifications
160
Shift Weights
161
Shift Weight Inspection
162
Clutch Offset Alignment Tool
168
Clutch Bushing Replacement Tool Kit
169
Clutch Compression Tool
172
Bushing Service
174
Ebs Drive Clutch Exploded View
176
Clutch Bushing Replacement Tool Kit
177
Removal and Installation
178
Roller Pin Removal Tool
190
Final Drive
191
Front Hub Assembly
193
Front Hub Disassembly
193
Awd Front Drive Axle Exploded View
196
Rear Hub Installation
208
Rear Hub Disassembly
209
Rear Hub Assembly
209
Rear Drive Shaft
210
Steering Post Assembly
152
Transmission
215
Transmission Mounting
216
Backlash Setting Tool
217
Special Tools
217
Torque Specifications
217
Transmission Removal
217
Transmission Installation
219
Transmission Disassembly
221
Transmission Assembly
228
Troubleshooting
234
Troubleshooting Checklist
234
Transmission Exploded View
235
Brakes
237
Specifications
238
Brake Noise Troubleshooting
241
Brake System Service Notes
241
Brake Bleeding / Fluid Change
243
Hydraulic Caliper Bleeding
243
Master Cylinder Installation
245
Master Cylinder Removal
245
Front Pad Removal
246
Front Pad Assembly
248
Brake Burnishing
249
Front Disc Inspection
249
Front Brake Disc
249
Front Caliper Disassembly
250
Front Caliper Removal
250
Front Caliper Inspection
251
Front Caliper Reassembly
251
Front Caliper Installation
252
Rear Brake Pad
254
Rear Caliper Removal/Inspection
255
Rear Caliper Assembly
256
Rear Brake Disc
257
Troubleshooting
259
Brakes Notes
261
Timing Light
262
ECM Operation
263
Electrical Components
264
Diagnostic Mode
266
Speedometer Removal
269
Speedometer Installation
269
Speedometer Troubleshooting
270
Fan Motor Tests
275
Fan Motor Current Draw
275
Etc Operation Test
276
Ignition System Testing Flow Chart
279
Ignition System Troubleshooting
280
Alternator Output Test
281
Timing Check Procedure
282
Charging System Testing Flow Chart
283
Battery Identification
284
Battery Charging
285
Battery Installation
286
Battery Testing
286
Battery Activation/Service
287
Conventional Battery Installation
288
Off Season Storage
290
High Beam Headlight Bulb Replacement
291
Headlamp Switch
294
Fuel Sender Test
295
Accessory Wire Hookup
296
Starter Motor Service
298
Voltage Drop Test
298
Armature Testing
300
Starter System Troubleshooting
298
Starter Drive
301
Starter System
302
4
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Polaris 2005 SPORTSMAN 400 Specifications
General
Brand
Polaris
Model
2005 SPORTSMAN 400
Category
Offroad Vehicle
Language
English
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