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2005 Sportsman MV7
Polaris 2005 Sportsman MV7 User Manual
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2005 SPORTSMAN MV
7
SER
VICE MANUAL
PN 9919963
2005 SPORTSMAN MV
7
SER
VICE MANUAL
PN 9919963
Printed in USA
9919963
PART #
Cvr_9919963 10/19/04 2:43 PM Page 1
2
Table of Contents
Chapter Index
4
Table of Contents
4
Model Identification
6
Serial Number Location
6
Publications Numbers / Replacement Keys
7
Publication Numbers
7
Paint Codes
7
2005 Sportsman MV
8
Jetting Chart
9
Special Tools
10
Standard Torque Specifications
15
Conversion Table
16
Glossary of Terms
18
Maintenance
19
Periodic Maintenance Chart
20
Maintenance and Lubrication
21
General
22
Polaris Lubricant Symbol Identification
25
Pre-Ride Inspection
28
Front Gearcase Lubrication
29
Transmission Lubrication/Linkage Inspection
30
Rear Gearcase Lubrication
31
Lubrication / Grease Points
32
Throttle Inspection
32
Idle Speed Adjustment
33
Chapter 1 Chapter 3
35
Fuel System
35
Fuel Lines
35
Vent Lines
36
Fuel Filter
36
Compression Test
36
Carburetor Draining
36
Battery Maintenance
37
Engine Mounts
37
Spark Plug
38
Liquid Cooling System
39
Cooling System Hoses
39
Radiator Coolant Level
40
Cooling System Pressure Test
40
Breather Filter / Line Inspection
42
Air Box Sediment Tube
42
Recoil Housing
43
PVT Drying & PVT Drain Plug
44
Oil and Filter Change
45
Toe Alignment
48
Exhaust Pipe
48
Auxiliary Brake Testing
51
Controls
52
Front Suspension
52
Rear Suspension
52
Warn ® Winch Operation
54
Tire Inspection
54
Cleaning and Storage
56
Maintenance Schedule
58
Maintenance Maintenance Schedule
59
Maintenance
35
Engine Exploded Views
60
Top End
63
Accessible Components
65
Piston Identification
65
Special Tools
65
Torque Specifications
66
Engine Fastener Torque Patterns
67
600 Engine Service Data
68
Cooling System Specifications
72
Cooling System Test
72
Chapter 5
74
Pvt System
74
Engine Installation Notes
74
Oil Flow
76
Rocker Arm/Pushrod Inspection
77
Cylinder Head Removal
77
Cylinder Head Warpage
78
Cylinder Head Disassembly/Inspection
78
Valve Inspection
80
Combustion Chamber
81
Valve Seat Reconditioning
81
Cylinder Head Assembly
83
Cylinder Head Reassembly
83
Valve Sealing Test
84
Valve Train Exploded View
84
Engine Head Reassembly
85
Cylinder Removal
87
Valve Lifter Removal/Inspection
87
Piston Removal
87
Cylinder Inspection
88
Piston Ring Installed Gap
91
Starter Bendix Removal/Inspection
92
Flywheel/Stator Removal/Inspection
93
Flywheel/Stator Installation
93
Engine Crankcase Disassembly/Inspection
95
Camshaft Inspection
103
Engine Crankcase Assembly
104
Troubleshooting
116
Table of Contents
119
Fuel Flow Diagram
122
Carburetor Jetting
123
Mikuni Jet Part Numbers
123
Jetting Guidelines
123
Assembly, CV Carburetor
124
Float System
126
Main System
126
Carburetor Inspection
128
Carburetor Cleaning
128
Carburetor Assembly
129
CV Carburetor System Function (4 Cycle)
124
Needle & Seat Leakage Test
130
Fuel Level
131
Fuel Pump Service
131
Fuel Pump Disassembly
131
Fuel Sender Service
132
Troubleshooting
132
Fuel System / Carburetion Notes
135
Plastic Insert Removal/Install
136
Side Panel Removal
137
Front Cover Removal/Install
138
Front Rack/Brushguard Removal/Install
140
Rear Rack/Brushguard Removal/Install
143
Warn ® Winch Removal/Installation
144
Headlight Pod Exploded View
147
Handlebar Block Installation Procedure
148
Body Assembly Exploded View
149
A-Arm Replacement
153
Rear Suspension Assembly
154
Strut Assembly
155
Front Strut Cartridge Replacement
156
Ball Joint Replacement
156
Decal Replacement
157
Steering Post Assembly
157
Clutch
159
Drive Clutch Exploded View
160
PVT Sealing and Ducting Components
160
PVT Operation Overview
161
Pvt Drying
162
PVT Overheating/Diagnosis
163
PVT Cover Removal/Install
164
PVT Disassembly
165
PVT Assembly/Inspection
166
Drive Clutch Spring Specifications
167
Shift Weights /Inspection
168
Shift Weight Inspection
169
Drive Clutch
169
Drive Clutch Reassembly
171
Drive Belt Removal/Inspection
172
Clutch Alignment/Offset
174
Clutch Offset
175
Drive Clutch Inspection
175
Moveable Sheave Bushing Inspection
176
Drive Belt Installation
174
Driven Clutch Disassembly/Assembly
177
Removal and Installation
184
Troubleshooting
185
Final Drive
187
Front Hub Assembly
191
Front Hub Disassembly
191
Awd Front Drive Axle Exploded View
194
Rear Hub Installation
206
Rear Hub Assembly
207
Rear Hub Disassembly/Assembly
207
Rear Drive Shaft Removal
208
Rear Driveshaft Installation
209
Rear Driveshaft Service
210
Rear Gearcase Service
212
Rear Gearcase Installation
215
Transmission
217
Transmission Exploded View
218
Transmission
220
Torque Specifications/Lubrication
220
Gear Shift Selector Removal
220
Transmission Removal
220
Transmission Installation
221
Transmission Disassembly
222
Transmission Reassembly
227
Brakes
233
Brake System Components
235
Front Caliper Exploded View
236
Rear Caliper Exploded View
236
Brake Noise Troubleshooting
237
Brake System Service Notes
237
Hydraulic Brake System Overview
238
Brake Bleeding / Fluid Change
239
Hydraulic Caliper Bleeding
239
Master Cylinder Installation
241
Master Cylinder Removal
241
Front Pad Removal
242
Front Pad Assembly
244
Brake Burnishing
245
Front Disc Inspection
245
Front Disc Removal/Replacement
245
Front Caliper Disassembly
246
Front Caliper Removal
246
Front Caliper Inspection
247
Front Caliper Reassembly
247
Front Caliper Installation
248
Rear Pad Removal
249
Rear Pad Installation
250
Rear Caliper Reassembly
251
Rear Caliper Assembly
252
Rear Caliper Removal/Inspection
251
Rear Disc Inspection
253
Troubleshooting
255
Brakes Notes
257
Chapter 9
257
Electrical
257
Gear Position Switch Test
258
Trigger Coil Gap Procedure
258
ECM Operation / Overview
259
Instrument Cluster Overview
260
Diagnostic Mode
262
Speedometer Removal/Installation
264
Speedometer Operation Troubleshooting
266
Fan Motor Current Draw
272
Etc Operation Test
273
Flywheel Identification
274
Ignition System Testing Flow Chart
276
Ignition System Troubleshooting
277
Alternator Output Test
279
Charging System Testing Flow Chart
280
Battery Identification
281
Load Test
283
Charging Procedure
284
Battery Charging
285
Battery Testing
286
Low Maintenance Battery Installation
286
Battery Load Test
286
Low Maintenance Battery Charging
287
High Beam Headlight Bulb Replacement
288
Fuel Sender Test
292
Starter Motor Removal
295
Voltage Drop Test
295
Armature Testing
297
Starter Drive
299
Starter System Testing Flow Chart
301
5
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Polaris 2005 Sportsman MV7 Specifications
General
Brand
Polaris
Model
2005 Sportsman MV7
Category
Offroad Vehicle
Language
English
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