SERVICEMANUAL
Foreword
ThismanualisdesignedprimarilyforusebyPolarisATVservicetechniciansinaproperlyequippedshop. Personsusingthismanualshouldhaveasoundknowledgeofmechanicaltheory,tooluse,andshopproceduresinordertoperformtheworksafelyandcorrectly.Thetechnicianshouldreadthetextandbefamiliar withserviceproceduresbeforestartingthework.Certainproceduresrequiretheuseofspecialtools.Use onlythepropertools,asspecified.Cleanlinessofpartsandtoolsaswellastheworkareaisofprimaryimportance.
Allreferencestoleftandrightsideofthevehiclearefromtheoperator’sperspectivewhenseatedinanormal ridingposition.
Thismanualincludesproceduresformaintenanceoperations,componentidentificationandunitrepair,along withservicespecificationsforthe2005PolarisSportsmanATVs.Atableofcontentsisplacedatthe beginningofeachchapter,andanalphabeticindexisprovidedattheendofthemanualforlocationofspecific pagenumbersandserviceinformation.Keepthismanualavailableforreferenceintheshoparea. Atthetimeofpublicationallinformationcontainedinthismanualwastechnicallycorrect.However,all materialsandspecificationsaresubjecttochangewithoutnotice.
Commentsorsuggestionsaboutthismanualmaybedirectedto:PolarisSalesInc.,ServicePublications Department,2100Hwy55Medina,Minnesota55340.
2005Sportsman400/500ATVServiceManual( PN9919425)
ECopyright2004PolarisSalesInc.Allinformationcontainedwithinthispublicationisbasedonthelatestproductinformationatthe timeofpublication.Duetoconstantimprovementsinthedesignandqualityofproductioncomponents,someminordiscrepanciesmay resultbetweentheactualvehicleandtheinformationpresentedinthispublication.Depictionsand/orproceduresinthispublicationare intendedforreferenceuseonly.Noliabilitycanbeacceptedforomissionsorinaccuracies.Anyreprintingorreuseofthedepictions and/orprocedurescontainedwithin,whetherwholeorinpart,isexpresslyprohibited.PrintedinU.S.A.
UNDERSTANDINGSAFETYLABELSANDINSTRUCTIONS
Throughouttheseinstructions,importantinformationisbroughttoyourattentionbythefollowingsymbols:
TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED!
DANGER
FailuretofollowDANGERinstructionswillresultinsevereinjuryordeathtotheoperator,bystanderorperson inspectingorservicingtheATV.
WARNING
FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtotheoperator,bystanderor personinspectingorservicingtheATV.
CAUTION:
ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoidpersonalinjury,orATVorproperty damage.
NOTE: ANOTEprovideskeyinformationtoclarifyinstructions.
Trademarks
Polarisacknowledgesthefollowingproductsmentionedinthismanual:
FLEXLOC,RegisteredTrademarkofSPSTechnologies
Loctite,RegisteredTrademarkoftheLoctiteCorporation
Nyogel,TrademarkofWm.F.NyeCo.
Fluke,RegisteredTrademarkofJohnFlukeMfg.Co.
MityVac,RegisteredTrademarkofNewardEnterprises,Inc.
Torx,RegisteredTrademarkofTextron
Hilliard,TrademarkoftheHilliardCorporation
Warn,TrademarkoftheWarnIndustries
SomePolarisfactorypublicationscanbedownloadedfrom www.polarisindustries.com orpurchasedfrom www.purepolaris.com orcontactyournearestPolarisdealer.
GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINALDRIVE BODYANDSTEERING TRANSMISSION BRAKES ELECTRICAL
GENERALINFORMATION 1.1
ModelIdentification1.2 SerialNumberLocation1.2 PublicationNumbers1.3 PaintCodes1.3 ............................. ReplacementKeys1.3 GeneralSpecifications-Sportsman400/5001.4-1.6 . SpecialTools1.7--1.12 ............................ StandardTorqueSpecifications1.13 ............ DecimalEquivalentChart1.14 ................. ConversionTable1.15 ........................ GlossaryofTerms1.16 ........................ Specs
MACHINEMODELNUMBERANDSERIALNUMBERLOCATION
Enginemodelnumberisonrecoilhousing(A).The machinemodelnumberandserialnumberare importantforvehicleidentification.Themachine serialnumberisstampedonthelowerleftsideof theframetube.(B)
GENERALINFORMATION 1.2 MODELIDENTIFICATION
MachineModelNumberIdentification YearDesignation BasicChassis DesignationEngineDesignation A05MH50AA ModelOption ENGINEDESIGNATION NUMBERS 42EH42PLESingle,L/C,SOHC4Stroke,ElectricStart 50EH50PLESingle,L/C,SOHC4Stroke,ElectricStart ............... VINIDENTIFICATION 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 4XAMH 50A*5P000000 VehicleDescriptor VehicleIdentifier Powertrain Engine Emissions Model Year PlantNo. IndividualSerialNo. BodyStyle CheckDigit WorldMfg.ID *Thiscouldbeeither anumberoraletter
Themachinemodelnumbermustbeusedwithanycorrespondenceregardingwarrantyorservice.
Whenevercorrespondingaboutanengine,besuretorefertotheenginemodelnumberandserialnumber.This informationcanbefoundonthestickerappliedtotherecoilhousingontherightsideofengine.(A)Anadditional numberisstampedonthecentertopofcrankcasebeneaththecylindercoolantelbow.
TRANSMISSIONI.D. NUMBER LOCATION A B Front
ThetransmissionI.D.numberislocatedontopofthetransmission snorkel,rightsideofmachine.
GENERALINFORMATION 1.3 PUBLICATION NUMBERS Year Model Owner’sManualPN Parts ManualPN Parts MicroFichePN
ATVPAINTINFORMATION
COLDWEATHERKITSFOR4CYCLEATVS
PN2871507) ACCESSORYENGINEHEATER REPLACEMENT KEYS Replacementkeyscanbemadefromtheoriginal key.Toidentifywhichseriesthekeyis,takethe firsttwodigitsontheoriginalkeyandrefertothe charttotherightfortheproperpartnumber. Series# PartNumber 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 31XX KeySeries Number
2005 Sportsman400 9919412 9919413 9919414 2005 Sportsman500 9919412 9919416 9919417 NOTE: Whenorderingservicepartsbesuretousethecorrectpartsmanual. NOTE: SomemanualscanbefoundatthePolariswebsite: www.polarisindustries.com
FRAMECOLOR-(All)P067MediumGlossBlack9440/8520147.
EngineHeater--(
MODEL: 2005Sportsman400 ..........
MODELNUMBER:A05MH42 .
ENGINEMODEL:425 ..
Category Dimension Length 83in./211cm
Width 48in./122cm
Height 48in./122cm
WheelBase 51in./129.5cm
GroundClearance 11in./27.94cm
DryWeight 703lbs./319kg
GrossVehicleWeight 1210lbs./549kg
OilCapacity 2.25qts./2.1ltr
CoolantCapacity 2.25qts./2.1ltr
FrontRackCapacity 90lbs./40.8kg
RearRackCapacity 180lbs./81.6kg
TowingCapacity 1225lbs./555.6kg
HitchTongueWeight 120lbs./54.4kg
BodyStyle SPIRIT
MODEL:
2005Sportsman500
MODELNUMBER:A05MH50 .
ENGINEMODEL:500 ..
Category Dimension Length 83in./211cm
Width 48in./122cm
Height 48in./122cm
WheelBase 51in./129.5cm
GroundClearance 11.25in./28.6cm
DryWeight 715lbs./324kg
GrossVehicleWeight 1222lbs./554kg
OilCapacity 2.25qts./2.1ltr
CoolantCapacity 2.25qts./2.1ltr
FrontRackCapacity 90lbs./40.8kg
RearRackCapacity 180lbs./81.6kg
TowingCapacity 1225lbs./555.6kg
HitchTongueWeight 120lbs./54.4kg
BodyStyle SPIRIT
GENERALINFORMATION 1.4
Drivetrain
TransmissionType DrumShiftH/L/N/R/P
TransmissionCapacity 32oz. FrontGearcaseCapacity 5oz.(147.8ml) GearRatio:Low High Rev. Final
23.91/1 10.49/1 16.30/1 3.82/1 ClutchType PVTNonEBS Belt 3211077
Steering/Suspension
FrontSuspension/Shock A--arm/MacPhersonStrut FrontTravel 8.2in./20.8cm
RearSuspension Style/Shock ProgressiveRateIndependent w/Twox2”Coil--overshocks RearTravel 9.5in./24.13cm GroundClearance 11in./27.94cm ShockPreloadAdjustment Front/Rear Springtension--Std. TurningRadius 65in./165.10cm ToeOut 0--1/16in/.0--.159mm
GENERALINFORMATION 1.5 MODEL: 2005SPORTSMAN400 .......... MODELNUMBER:A05MH42AB,AG,AH . ENGINEMODEL:EH42PLE .. Engine Platform Fuji4stroke,SingleCylinder EngineModelNumber EH42PLE05 EngineDisplacement 425cc NumberofCylinders 1 Bore&Stroke(mm) 87.9x70mm CompressionRatio 9.2:1 CompressionPressure 50--90psi EngineIdleSpeed 1100 ± 200Rpm CoolingSystem/Capacity Liquid/2.25qts.(2.1L) OverheatWarning HOTonInstrumentCluster Lubrication PressurizedDrySump OilRequirements Polaris0W--40 ExhaustSystem SinglePipe Carburetion Carburetormodel MikuniBST34mm MainJet 172.5 PilotJet 40 JetNeedle 4GAC33--3 NeedleJet Q--0(829) PilotScrew 2.75TurnsOut PilotAirJet 160 FloatHeight 13 ± 1mm(0.51 ± 0.40“) FuelDelivery FuelPump FuelCapacity/Requirement 4.25gal.(19.9L) 87Octane(minimum) 89Oxygenated Electrical AlternatorOutput 240w@3000RPM VoltageRegulator 3--Phase--SurePower Lights:HighBeam 50watts LowBeam 37watts Brake 26.9watts Tail 8.26watts Worklight 12watts IgnitionSystem DC/CDIIgnition IgnitionTiming 30°± 2° BTDC@5000RPM CircuitProtection SolidState Sparkplug/Gap NGKBKR5E/.036in /0.9mm Battery/Model/AmpHr Maintenance--Free--12AmpHr Starting Electric/RecoilBackup InstrumentCluster LCD
Wheels/Brakes Wheel/TireSize--Front
Wheel/TireSize--Rear
AirPress.F/RTires 5psiFront/5psiRear Brake--Front DualHydraulicDisc Brake--Rear SingleHydraulicDisc BrakeFluid PolarisDOT3BrakeFluid JETTINGCHART Altitude Meters (Feet) AMBIENTTEMPERATURE 0--1800 (0--6000) above1800 (above6000) Below40° F Below5° C +40° Fto+80° F +5° Cto+28° C 177.5172.5 170 165
Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10WH 20--40 34--38° Second Spring Black (5630710) (5631356) (7041782) (5133920) (7041782) (7041157) (7042202) 34--38° (5133920) Black Blu/Grey Blu/Grn DrivenHelixPosition:2--2
25x8--12/4--156
25x11--12/4--156
CLUTCHCHART
Drivetrain
TransmissionType DrumShiftH/L/N/R/P
Steering/Suspension
CLUTCHCHART
GENERALINFORMATION 1.6 MODEL: 2005SPORTSMAN500 .......... MODELNUMBER:A05MH50AB,AC,AG,AH . ENGINEMODEL:EH50PLE .. Engine Platform Fuji4stroke,SingleCylinder EngineModelNumber EH50PLE13 EngineDisplacement 499cc NumberofCylinders 1 Bore&Stroke(mm) 92x75mm CompressionRatio 10:2 CompressionPressure 50--90psi EngineIdleSpeed 1100 ± 200Rpm CoolingSystem/Capacity Liquid/2.25qts.(2.1L) OverheatWarning HOTonInstrumentCluster Lubrication PressurizedDrySump OilRequirements Polaris0W--40 ExhaustSystem SinglePipe Carburetion Carburetormodel MikuniBST40mm MainJet 155 PilotJet 40 JetNeedle 6MGH1--94--3 NeedleJet X--6M PilotScrew 2TurnsOut PilotAirJet 160 FloatHeight 14.7 ± 1mm(0.58 ± 0.40“) FuelDelivery/TankCapacity FuelPump FuelCapacity/Requirement 4.25gal.(19.9L) 87Octane(minimum) 89Oxygenated Electrical AlternatorOutput 240w@3000RPM VoltageRegulator 3--Phase--SurePower Lights:HighBeam 50watts LowBeam 37watts Brake 26.9watts Tail 8.26watts Worklight 12watts CircuitProtection SolidState IgnitionSystem DC/CDIIgnition IgnitionTiming 30°± 2° BTDC@5000RPM Sparkplug/Gap NGKBKR6E/.036in /0.9mm Battery/Model/AmpHr Maintenance--Free--12AmpHr Starting Electric/RecoilBackup InstrumentCluster LCD
TransmissionFluidCapacity 32oz. FrontGearcaseCapacity 5oz.(147.8ml) GearRatio:Low High Rev. Final 23.91/1 10.49/1 16.3/1 3.82/1 ClutchType PVTw/EBS Belt 3211095
Wheels/Brakes WheelSize--Front
WheelSize--Rear
AirPress.F/RTires 5psiFront/5psiRear Brake--Front DualHydraulicDisc Brake--Rear SingleHydraulicDisc BrakeFluid PolarisDOT3BrakeFluid
Altitude Meters (Feet) AMBIENTTEMPERATURE 0--1800 (0--6000) above1800 (above6000) Below40° F Below5° C +40° Fto+80° F +5° Cto+28° C 160 155 152.5 147.5
FrontSuspension/Shock A--arm/MacPhersonStrut FrontTravel 8.2in./20.8cm RearSuspension Style/Shock ProgressiveRateIndependent RearTravel 9.5in./24.13cm GroundClearance 11in./27.94cm ShockPreloadAdjustment Front/Rear Springtension--Std. TurningRadius 65in./165.10cm ToeOut 0--1/16in/.0--.159mm
25x8--12/4--156
25x11--12/4--156
JETTINGCHART
Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10WH 10RH EBS 41--37° Second Spring Wht/Yel (5630710) (5630709) (7041635) (5131674) (7041635) (7041157) (7041157) Wht/Yel (5131674) Blu/Grn Blu/Grn EBS 41--37° *EBSmodelsrequirenohelix/springadjustment
TOOLDESCRIPTION CHAPTERTOOLUSEDIN
ValveClutchAdjuster 2 2872105 WaterPumpMechanicalSealPuller 2 8712100or8712500 Tachometer 2,10 2200634
PA--44689
ValveSeatReconditioningKit 3 2870390 PistonSupportBlock 3 2871043 FlywheelPuller 3 2 871283 Crankshaft/WaterPumpSealInstallKit 3 5131135 WaterPumpInstallKit 3 2870569 CrankshaftTruingStand 5 2872314 CarburetorFloatAdjustmentTool 4 2870975 MityVac t PressureTestTool 3,4,9 2870871 BallJointReplacementTool 5 2870872 ShockSpannerWrench 2,5 2870623 ShockAbsorberSpringCompressionTool 5 2871572 StrutRodWrench 5 2871573 LHStrutSpringCompressor 5 2871574 RHStrutSpringCompressor 5 7052069 ChargingNeedle 5 2200421 GasShockRechargingKit 5 2871352 ShockRodHoldingTool 5 2871351 Fox t ShockIFPDepthTool 5 2870506 ClutchPuller 6 9314177 ClutchHoldingWrench 6 2871358 ClutchHoldingFixture 6 2870341 DriveClutchSpiderRemovalandInstallTool 6 2870654 ClutchOffsetAlignmentTool 6 2870913 DrivenClutchPuller 6 2870910 RollerPinTool 6 2871226 ClutchBushingReplacementToolKit 6 2870386 PistonPinPuller 6 2872292 EBSClutchAlignmentTool 6 2201379 EBSBushingReplacementKit 6 8700220 ClutchCompressionTool 6 2871025 ClutchBushingReplacementToolKit 6 2871199 SealSleeveInstallationToolKit 5,7 2870888 HilliardClutchGarterSpringInstallationTool 7 2872608 RollerPinRemovalTool 7 8700226 CVBootClampPliers 7 2871701 (Partof
GENERALINFORMATION 1.7
SPECIALTOOLS PARTNUMBER
2871702 Kit) 21/8inchWrench 8 2871697 (Partof 2871702 Kit) CenterDriveBushingTool 8 2871695 (Partof 2871702 Kit) BacklashSettingTool 8 2871698 (Partof 2871702 Kit) RearOutputSealDriver 8 2871699 (Partof 2871702 Kit) RearDriveshaftSealGuide 8 2871282 BearingSealDriver(50mm) 8 PV--43568 Fluke t 77DigitalMultimeter 10 2870630 TimingLight 10 2870836 BatteryHydrometer 10
GENERALINFORMATION 1.8 SPECIALTOOLS, CONT’D 2460761
10 2871745 StaticTimingLightHarness 10 NOTE: PolarisdealerscanorderthetoolslistedabovethroughtheirPolarisSpecialServiceToolscatalog.
SpecialToolsmayberequiredwhileservicingyour machine.Someofthetoolslistedaremandatoryand othertoolsmaybesubstitutedwithasimilartool,if available.PolarisreccommendstheuseofPolaris
StandardToolsandEngineTools PU--45432--Caliperor ABasicCaliper BasicMicrometer 2871043--FlywheelPuller 2870773--C--ClipInstallTool 2870967--SlottedNutSocket 8700229--FlywheelHolder&Adapter StandardToolsandEngineTools 2870569--CrankshaftTrueKit 2870386--PistonPinPuller 2871445--PistonPinPullerAdapter 2870968--CounterBalancePuller PA--44689--Valve/ClutchAdjuster 2870390--PistonSupportBlock PV--43527OilFilterWrench
HallSensorProbeHarness
SPECIALTOOLS
specialtoolswhenservicinganyPolarisproduct.
GENERALINFORMATION 1.9 StandardToolsandEngineTools 2870303--HoneKit 2870305--StoneReplacementKit 2870459--DialIndicator 2870588--HoneOil(12oz.) 2872105--WaterPumpSealPuller PV--35667--A--CylinderLeak downTester 2200634--ValveSeat ReconditioningKit Clutch(PVT)Tools 2870506--DriveClutchPuller 2870913--DrivenClutchPuller 2870654--ATVClutchAlignTool 2872292--EBSClutchAlignTool 9914177--A--DriveClutchHoldingTool 8700220--ClutchCompressionTool 2871283--Crank/WaterPumpSeal InstallKit
GENERALINFORMATION 1.10 Clutch(PVT)Tools 2870341--DriveClutchSpider RemovalTool 2870910--RollPinTool 2871226--ClutchBushing ReplacementKit 2201379--EBSBushing ReplacementKit 2870338--SpiderNutSocket 2871358--ClutchHoldingFixture 2871025--ClutchBushingReplace ToolKit SuspensionTools 2870871--ATVBallJointToolKit 2871071--ShockBodyHoldingTool 2870623--ShockSpringCompressor 2871572--StrutRodWrench 2871573&2871574--Strut SpringCompressor 8700225&8700226--CVBoot ClampPliers
GENERALINFORMATION 1.11 SuspensionTools 2870872--ShockSpannerWrench 2872608--RollPinRemovalTool TransmissionTools 2871702--ShaftDriveTransmission &FrontGearcaseToolKit 2871351--ShockIFPDepthTool 2871282--Bearing/SealDriver (50mm) ElectricalTools PV--43568--Fluke77Multimeter 2870836--BatteryHydrometer 8712500-Tachometer RPM PV--39951--A-Tachometer PV--39617--CurrentClamp Fuel&Brake Systems 2870975--MityVac
GENERALINFORMATION 1.12 ElectricalTools 2870630--TimingLight 2871745--StaticTimingLightHarness 2460761--HallSensorProbeHarness PV--39991--PeakReadingAdapter PV--37453--ChristieSe--Sulfating Multi--Battery Charger PV--63070--ChristieMulti--Battery Charger
STANDARDTORQUESPECIFICATIONS
Thefollowingtorquespecificationsaretobeusedasageneralguideline.Thereareexceptionsinthesteering, suspension,andengineareas.Alwaysconsulttheexplodedviewsineachmanualsectionfortorquevaluesof fastenersbeforeusingstandardtorque.
BoltSizeThreads/InGrade2Grade5Grade8
Torquein.lbs. (Nm)
#10-2427(3.1)43(5.0)60(6.9)
#10-3231(3.6)49(5.6)68(7.8)
Torqueft.lbs.(Nm)*
1/4-205(7)8(11)12(16) ................................................
1/4-286(8)10(14)14(19)
5/16-1811(15)17(23)25(35) ............................................
5/16-2412(16)19(26)29(40)
3/8-1620(27)30(40)45(62)
3/8-2423(32)35(48)50(69)
7/16-1430(40)50(69)70(97) ............................................
7/16-2035(48)55(76)80(110) 1/2-1350(69)75(104)110(152)
1/2-2055(76)90(124)120(166) ...........................................
Metric
6x1.072-78In.lbs. 8x1.2514-18ft.lbs. 10x1.2526-30ft.lbs.
* Toconvertft.lbs.toNmmultiplyfootpoundsby.1.382
* ToconvertNmtoft.lbs.multiplyNmby.7376.
SPECIFICTORQUEVALUESOFFASTENERS
RefertoexplodedviewsintheappropriatesectionTorqueConversions
GENERALINFORMATION 1.13
SAETAPDRILL SIZES
ThreadSize/DrillSize ThreadSize/DrillSize
#0-803/64 #1-6453 #1-7253 #2-5651 #2-6450 #3-485/64 #3-5645 #4-4043 #4-4842 #5-4038 #5-4437 #6-3236 #6-4033 #8-3229 #8-3629 #10-2424 #10-3221 #12-2417 #12-284.6mm 1/4-207 1/4-283 5/16-18F 5/16-24I 3/8-16O 3/8-24Q 7/16-14U 7/16-2025/64
1/2-1327/64 1/2-2029/64 9/16-1231/64 9/16-1833/64 5/8-1117/32 5/8-1837/64 3/4-1021/32 3/4-1611/16 7/8-949/64 7/8-1413/16 1-87/8 1-1259/64 11/8-763/64 11/8-1213/64 11/4-717/64 11/4-12111/64 11/2-6111/32 11/2-12127/64 13/4-519/16 13/4-12143/64 2-41/2125/32 2-12159/64 21/4-41/221/32 21/2-421/4 23/4-421/2 3-423/4
DECIMALEQUIVALENTS
3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32
1/64.0156 1/32.03121mm=.0394″ .............. 3/64.0469 1/16.0625 5/64.07812mm=.0787″ ................... 3/32.0938 ........... 7/64.10943mm=.1181″ ................. 1/8..1250 9/64.1406 5/32.15634mm=.1575″ .............. 11/64.1719 3/16.18755mm=.1969″ .............. 13/64.2031 7/32.2188 15/64.23446mm=.2362″ .................. 1/4.25 17/64.26567mm=.2756″ 9/32.2813 19/64.2969 5/16.31258mm=.3150″ .............. 21/64.3281 11/32.34389mm=.3543″ 23/64.3594 3/8.375 25/64.390610mm=.3937″ .................. 13/32.4063 27/64.421911mm=.4331″ 7/16.4375 29/64.4531 ............... 15/32.468812mm=.4724″ ............ 31/64.4844 1/2.513mm=.5118 33/64.5156 17/32.5313 ......... 35/64.546914mm=.5512″ 9/16.5625 37/64.578115mm=.5906″ 19/32.5938 39/64.6094 ............... 5/8.62516mm=.6299″ 41/64.6406 21/32.656317mm=.6693″ 43/64.6719 11/16.6875 .......... 45/64.703118mm=.7087″ 23/32.7188 47/64.734419mm=.7480″ 3/4.75 .... 49/64.7656 ............... 25/32.781320mm=.7874″ 51/64.7969 13/16.812521mm=.8268″ 53/64.8281 ............... 27/32.8438 55/64.859422mm=.8661″ 7/8.875 57/64.890623mm=.9055″ .................. 29/32.9063 ......... 59/64.9219 15/16.937524mm=.9449″ 61/64.9531 31/32.968825mm=.9843 ............ 63/64.9844 ............... 11.0
GENERALINFORMATION 1.14
SIZES TapSize DrillSize Decimal Equivalent Nearest Fraction
10x1.50 11x1.50 12x1.50 12x1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406
METRICTAPDRILL
3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25
3/32
CONVERSIONTABLE
UnitofMeasure
Multipliedby
Convertsto ft.lbs. x12 =in.lbs. in.lbs. x.0833 =ft.lbs. ft.lbs. x1.356 =Nm in.lbs. x.0115 =kg-m Nm x.7376 =ft.lbs. kg-m x7.233 =ft.lbs. kg-m x86.796 =in.lbs. kg-m x9.807 =Nm in. x25.4 =mm mm x.03937 =in. in. x2.54 =cm mile(mi.) x1.6 =km km x.6214 =mile(mi.) Ounces(oz) x28.35 =Grams(g) FluidOunces(fl.oz.) x29.57 =CubicCentimeters(cc) CubicCentimeters(cc) x.03381 =FluidOunces(fl.oz.) Grams(g) x0.035 =Ounces(oz) lb. x.454 =kg kg x2.2046 =lb.
Cubicinches(cuin) x16.387 =Cubiccentimeters(cc) Cubiccentimeters(cc) x0.061 =Cubicinches(cuin)
Imperialpints(Imppt) x0.568 =Liters(l) Liters(l) x1.76 =Imperialpints(Imppt) Imperialquarts(Impqt) x1.137 =Liters(l) Liters(l) x0.88 =Imperialquarts(Impqt) Imperialquarts(Impqt) x1.201 =USquarts(USqt) USquarts(USqt) x0.833 =Imperialquarts(Impqt) USquarts(USqt) x0.946 =Liters(l) Liters(l) x1.057 =USquarts(USqt) USgallons(USgal) x3.785 =Liters(l) Liters(l) x0.264 =USgallons(USgal) Pounds-forcepersquareinch(psi) x6.895 =Kilopascals(kPa) Kilopascals(kPa) x0.145 =Pounds-forcepersquareinch(psi) Kilopascals(kPa) x0.01 =Kilograms-forcepersquarecm Kilograms-forcepersquarecm x98.1 =Kilopascals(kPa)
GENERALINFORMATION 1.15
°
°
°
°
°
°
°
°
π(3.14) xR2 xH(height) =CylinderVolume
Cto
F:9(
C+40) ÷ 5-40=
F
Fto
C:5(
F+40) ÷ 9-40=
C
GLOSSARYOF TERMS
ABDC: Afterbottomdeadcenter.
ACV: Alternatingcurrentvoltage.
Alternator: Electricalgeneratorproducingvoltagealternatingcurrent.
ATDC: Aftertopdeadcenter.
BBDC: Beforebottomdeadcenter.
BDC: Bottomdeadcenter.
BTDC: Beforetopdeadcenter.
CC: Cubiccentimeters.
CenterDistance: Distancebetweencenterofcrankshaftandcenterofdrivenclutchshaft.
ChainPitch: Distancebetweenchainlinkpins(No.35=3/8″ or1cm).Polarismeasureschainlengthinnumberofpitches. CI: Cubicinches.
ClutchButtons: Plasticbushingswhichaidrotationofthemovablesheaveinthedriveanddrivenclutch.
ClutchOffset: Driveanddrivenclutchesareoffsetsothatdrivebeltwill staynearlystraightasitmovesalongtheclutchface.
ClutchWeights: Threeleversinthedriveclutchwhichrelativetotheirweight,profileandengineRPMcausethedrive clutchtocloseandgripthedrivebelt.
CrankshaftRun-Out: Run-outor“bend”ofcrankshaftmeasuredwithadialindicatorwhilecrankshaftissupported betweencentersonVblocksorrestingincrankcase.MeasureatvariouspointsespeciallyatPTO.
DCV: Directcurrentvoltage.
DialBoreGauge: Acylindermeasuringinstrumentwhichusesadialindicator.Goodforshowingtaperand out-of-roundinthecylinderbore.
ElectricalOpen: Opencircuit.Anelectricalcircuitwhichisn’tcomplete.
ElectricalShort: Shortcircuit.Anelectricalcircuitwhichiscompletedbeforethecurrentreachestheintendedload. (i.e.abarewiretouchingthechassis).
EndSeals: Rubbersealsateachendofthecrankshaft.
EngagementRPM: EngineRPMatwhichthedriveclutchengagestomakecontactwiththedrivebelt. ft.: Foot/feet.
FootPound: Ft.lb.Aforceofonepoundattheendofaleveronefootinlength,appliedinarotationaldirection.
g: Gram.Unitofweightinthemetricsystem.
gal.: Gallon.
ID: Insidediameter. in.: Inch/inches.
InchPound: In.lb.12in.lbs.=1ft.lb.
kg/cm 2 : Kilogramspersquarecentimeter.
kg-m: Kilogrammeters.
Kilogram/meter: Aforceofonekilogramattheendofaleveronemeterinlength,appliedinarotationaldirection. lorltr: Liter.
lbs/in 2 : Poundspersquareinch.
LeftorRightSide: Alwaysreferredtobasedonnormaloperatingpositionofthedriver.
m: Meter/meters.
Mag: Magneto.
MagneticInduction: Asaconductor(coil)ismovedthroughamagneticfield,avoltagewill begeneratedinthe windings.Mechanicalenergyisconvertedtoelectricalenergyinthestator. mi.: Mile/miles.
mm: Millimeter.Unitoflengthinthemetricsystem.1mm=approximately.040″
Nm: Newtonmeters.
OD: Outsidediameter.
Ohm: Theunitofelectricalresistanceopposingcurrentflow.
oz.: Ounce/ounces.
PistonClearance: Totaldistancebetweenpistonandcylinderwall. psi.: Poundspersquareinch.
PTO: Powertakeoff.
PVT: PolarisVariableTransmission(DriveClutchSystem)
qt.: Quart/quarts.
Regulator: Voltageregulator.Regulatesbatterychargingsystemoutput atapprox.14.5DCVasengineRPMincreases.
ReservoirTank: Thefilltankintheliquidcoolingsystem.
Resistance: Inthemechanicalsense,frictionorload.Intheelectricalsense,ohms,resultinginenergyconversiontoheat.
RPM: Revolutionsperminute.
SeizedPiston: Gallingofthesidesofapiston.Usuallythereisatransferofaluminumfromthepistonontothecylinderwall.
Possiblecauses:1)improperlubrication;2)excessivetemperatures;3)insufficientpistonclearance;4)stuckpistonrings.
StatorPlate: Theplatemountedundertheflywheelsupportingthebatterychargingcoils.
TDC: Topdeadcenter.Piston’smostoutwardtravelfromcrankshaft.
Volt: Theunitofmeasureforelectricalpressureofelectromotiveforce.Measuredbyavoltmeterinparallelwiththecircuit.
Watt: Unitofelectricalpower.Watts=amperesxvolts.
WOT: Wideopenthrottle.
GENERALINFORMATION 1.16
PeriodicMaintenanceChart2.2-2.5
LubricantandMaintenanceProductNumbers2.6--2.7 ATVComponentLocations2.8 LubricationCharts2.9 ........................
MAINTENANCE 2.1
FrontGearcaseLubrication2.10-2.11 TransmissionLubrication2.11-2.12 .................. LubricationsPoints2.12--2.13 ....................... TransmissionLinkageAdjustment2.13 .......... Carburetor/ThrottleAdjustments2.13-2.16 .......... FuelSystem2.16-2.17 ............................. CompressionTest2.18 ........................ BatteryMaintenance2.19 ...................... CoolantSystemMaintenance2.19-2.21 .............. AirFilterService2.21-2.22 AirBoxSedimentTubeService2.22 BreatherFilter2.23 ........................... RecoilHousing2.23 OilChange/Filter2.24-2.26 ValveClearance2.26-2.27 SteeringandToeAlignment2.27-2.30 ............... ExhaustSystemMaintenance2.31 BrakeSystemService2.31-2.32 .................... SuspensionService2.33 ...................... Controls2.33 ................................. WheelRemoval/Installation2.34 ................ TireInspection2.34 ........................... CompartmentStorage2.35 .................... Warnt WinchOperation2.36--2.37 .................. CleaningandStorageofATV2.38--2.39 ..............
PERIODICMAINTENANCE CHART
Carefulperiodicmaintenancewillhelpkeepyourvehicleinthesafest,mostreliablecondition.Inspection, adjustmentandlubricationofimportantcomponentsareexplainedintheperiodicmaintenancechart. Inspect,clean,lubricate,adjustandreplacepartsasnecessary.Wheninspectionrevealstheneedfor replacementparts,usegenuinePolarispartsavailablefromyourPolarisdealer.
NOTE: Serviceandadjustmentsarecritical.Ifyou’renotfamiliarwithsafeserviceandadjustment procedures,haveaqualifieddealerperformtheseoperations.
Maintenanceintervalsinthefollowingchartarebaseduponaverageridingconditionsandanaveragevehicle speedofapproximately10milesperhour.Vehiclessubjectedtosevereusemustbeinspectedandservicedmore frequently.
SevereUseDefinition
S
Frequentimmersioninmud,waterorsand S Racingorrace-stylehighRPMuse S Prolongedlowspeed,heavyloadoperation S Extendedidle S Shorttripcoldweatheroperation
Payspecialattentiontotheoillevel.Ariseinoillevelduringcoldweathercanindicatecontaminantscollecting intheoilsumporcrankcase.Changeoilimmediatelyiftheoillevelbeginstorise.Monitortheoillevel,andif itcontinuestorise,discontinueuseanddeterminethecauseorseeyourdealer.
MaintenanceChartKey
Thefollowingsymbolsdenotepotentialitemstobeawareofduringmaintenance:
H= CAUTION:Duetothenatureoftheseadjustments,itisrecommendedthisservicebeperformed byanauthorizedPolarisdealer.
"= SEVEREUSEITEM----Ifvehicleissubjectedtosevereuse,decreaseintervalby50% (SevereUseisdefinedasfrequentvehicleimmersioninmud,waterorsand,racingorrace-stylehighrpm use,prolongedlowspeed-heavyloadoperationorextendedidle.Morepreventativemaintenanceis requiredundertheseconditions.Fluidchanges,cable,chainandchassislubricationarerequiredmore frequently.Forengineoil,shorttripcoldweatherridingalsoconstitutessevereuse Payspecialattention tooillevel.Arisingoillevelincoldweathercanindicatecontaminantscollectingintheoilsumpor crankcase.Changeoilimmediatelyandmonitorlevel.Ifoillevelbeginstorise,discontinueuseand determinecause.)
E= EmissionControlSystemService(California)
NOTE: Inspectionmayrevealtheneedforreplacementparts.AlwaysusegenuinePolarisparts.
WARNING: Improperlyperformingtheproceduresmarkedwitha J couldresultincomponentfailureandlead toseriousinjuryordeath.HaveanauthorizedPolarisdealerperformtheseservices.
MAINTENANCE 2.2
MAINTENANCEANDLUBRICATION
MAINTENANCE 2.3
PeriodicMaintenanceChart Item MaintenanceInterval (whichevercomesfirst) Remarks Hours Calendar Miles (Km) J Steering Pre-Ride Makeadjustmentsasneeded.SeePre-Ride
7 " Frontsuspension
j
" Rearsuspension Pre-Ride Tires Pre-Ride " Brakefluidlevel Pre-Ride " Brakelevertravel Pre-Ride Brakesystems Pre-Ride Wheels/fasteners Pre-Ride Framefasteners Pre-Ride " E Engineoillevel Pre-Ride " E Airfilter,pre-filter Daily Inspect;cleanoften " E Airboxsediment tube Daily Draindepositswhenvisible Coolant (ifapplicable) Daily Checkleveldaily,changecoolantevery2years Headlamp/tail lamp Daily
" E Airfilter, mainelement Weekly Inspect;replaceasneeded Recoilhousing Weekly
J Brakepadwear 10H Monthly
Battery
Monthly
" Frontgearcaseoil
25H Monthly
"
25H Monthly
" Reargearcaseoil
25H Monthly
" Transmissionoil 25H Monthly
Inspectlevel;changeyearly
Performtheseproceduresmoreoftenforvehicles
E EmissionControlSystemService(California)
services.
Ch kli t P 1
Pre-Ride
ChecklistonPage1.7.
Checkoperation;applydielectricgreaseifreplacing
Drainwaterasneeded,checkoftenifoperating inwetconditions "
60(100) Inspectperiodically
20H
125(200) Checkterminals;clean;test
(ifequipped)
155(250) Inspectlevel;changeyearly
Middlegearcase oil(ifequipped)
155(250) Inspectlevel;changeyearly
(ifequipped)
155(250) Inspectlevel;changeyearly
155(250)
"
subjectedtosevereuse.
J HaveanauthorizedPolarisdealerperformthese
MAINTENANCE 2.4
PeriodicMaintenanceChart Item MaintenanceInterval (whichevercomesfirst) Remarks Hours Calendar Miles (Km) " E Enginebreather filter(ifequipped) 25H Monthly 155(250) Inspect;replaceifnecessary " E Engineoilchange (break-in) 25H 1M 155(250) Performabreak-inoilchangeatonemonth " General lubrication 50H 3M 310(500) Lubricateallfittings,pivots,cables,etc. ShiftLinkage 50H 6M 310(500) Inspect,lubricate,adjust J Steering 50H 6M 310(500) Lubricate " Frontsuspension 50H 6M 310(500) Lubricate " Rearsuspension 50H 6M 310(500) Lubricate Carburetorfloat bowl 50H 6M 310(500) Drainbowlperiodicallyandpriortostorage J E ThrottleCable/ ETCSwitch 50H 6M 310(500) Inspect;adjust;lubricate;replaceifnecessary J E Chokecable 50H 6M 310(500) Inspect;adjust;lubricate;replaceifnecessary E Carburetorair intakeducts/ flange 50H 6M 310(500) Inspectductsforpropersealing/airleaks Drivebelt 50H 6M 310(500) Inspect;adjust;replaceasneeded Coolingsystem (ifapplicable) 50H 6M 310(500) Inspectcoolantstrength seasonally;pressuretest
" E Engineoilchange 100H 6M 620 (1000) Performabreak-inoilchangeat25hours/one month " E Oilfilterchange 100H 6M 620 (1000) Replacewithoilchange " E Oiltankventhose 100H 12M 620 (1000) Inspectrouting,condition J E Valveclearance 100H 12M 620 (1000) Inspect;adjust " Performtheseproceduresmoreoftenforvehicles subjectedtosevereuse. E EmissionControlSystemService(California) J HaveanauthorizedPolarisdealerperformthese services.
MAINTENANCEANDLUBRICATION
systemyearly
MAINTENANCE 2.5
PeriodicMaintenanceChart Item MaintenanceInterval (whichevercomesfirst) Remarks Hours Calendar Miles (Km) J E Fuelsystem 100H 12M 620 (1000) Checkforleaksattankcap,lines,fuelvalve,filter,pump,carburetor;replacelineseverytwo years J E Fuelfilter 100H 12M 620 (1000) Replaceyearly " Radiator (ifapplicable) 100H 12M 620 (1000) Inspect;cleanexternal surfaces " Coolinghoses (ifapplicable) 100H 12M 620 (1000) Inspectforleaks " Enginemounts 100H 12M 620 (1000) Inspect Exhaustmuffler/ pipe 100H 12M 620 (1000) Inspect J E Sparkplug 100H 12M 620 (1000) Inspect;replaceasneeded J E IgnitionTiming 100H 12M 620 (1000) Inspect " Wiring 100H 12M 620
Inspectforwear,routing, security;applydielectricgreasetoconnectors subjectedtowater,mud,etc. J Clutches(drive anddriven) 100H 12M 620
Inspect;clean;replacewornparts J Frontwheel bearings 100H 12M 1000
Inspect;replaceasneeded J Brakefluid 200H 24M 1240 (2000) Changeeverytwoyears Sparkarrestor 300H 36M 1860 (3000) Cleanout E Idlespeed Adjustasneeded J Toeadjustment Inspectperiodically;adjustwhenpartsarereplaced " J Auxiliarybrake Inspectdaily;adjustasneeded Headlightaim Adjustasneeded " Performtheseproceduresmoreoftenforvehicles subjectedtosevereuse. E EmissionControlSystemService(California) J HaveanauthorizedPolarisdealerperformthese services.
MAINTENANCEANDLUBRICATION
(1000)
(1000)
(1600)
PartNo.
FoggingOil(12oz.Aerosol) 2871098
2870791
Premium2CycleEngineOil(Quart)(12 Count) 2871281
EngineOil(Quart)Premium4Synthetic 0W--40(4--Cycle)(12Count) 2871844
EngineOil(Gallon)Premium4Synthetic 0W--40(4--Cycle)(4Count) 2871567
EngineOil(16Gallon)Premium4 Synthetic0W--40(4--Cycle)
PremiumSyntheticAGLGearcaseLube (12oz.bottle)(12Count) 2873603 PremiumSyntheticAGLGearcaseLube (1Gal.)(4Count) 2871653
2873602
PremiumATVAngleDriveFluid (8oz.)(12Count) 2872276
PremiumATVAngleDriveFluid (2.5Gal)(2Count) 2870465 OilPumpfor1GallonJug 2871654
PremiumDemandDriveHubFluid (8oz.)(12Count) 2872277
PremiumDemandDriveHubFluid (2.5gal.)(2Count) Grease/SpecializedLubricants 2871322
PartNo. Description Additives/Sealants/ThreadLockingAgents/ Misc. 2870585 Loctitet PrimerN,Aerosol,25g 2871956 Loctitet ThreadSealant565 (50ml.)(6Count) 2871949 Loctitet Threadlock242 (50ml.)(10Count) 2871950 Loctitet Threadlock242 (6ml.)(12Count) 2871951 Loctitet Threadlock262 (50ml.)(10Count) 2871952 Loctitet Threadlock262 (6ml.)(12Count) 2871953 Loctitet Threadlock271 (6ml.)(12Count) 2871954 Loctitet Threadlock271 (36ml.)(6Count) 2870584 Loctitet 680-RetainingCompound (10ml.) 2870587 Loctitet 518GasketEliminator/Flange Sealant(50ml.)(10Count) 2871326 PremiumCarbonClean (12oz.)(12Count) 2870652 FuelStabilizer(16oz.)(12C ount) 2871957 BlackRTVSiliconeSealer (3oz.tube)(12Count) 2871958 BlackRTVSiliconeSealer (11oz.cartridge)(12Count) 2870990 DOT3BrakeFluid(12Count) 2871557 CrankcaseSealant,3-Bond1215(5oz.) 2872893 EngineDegreaser(12oz.)(12Count)
MAINTENANCE 2.6
PRODUCTS
POLARISLUBRICANTS,MAINTENANCEANDSERVICE
Description
EngineLubricant
Gearcase/TransmissionLubricants
GreaseGunKit
DielectricGrease(Nyogelt ) Coolant 2871323 60/40Coolant(Gallon)(6Count) 2871534 60/40Coolant(Quart)(12Count) NOTE: Eachitemcanbepurchasedseparatelyat yourlocalPolarisdealer.
NOTE: Thenumbercountindicatedbyeachpart
POLARISLUBRICANTSYMBOLIDENTIFICATION ADF AGL PolarisAllSeasonGrease PolarisDOT3 BrakeFluid PolarisDemand DriveHubFluid PolarisATV AngleDriveFluid PolarisSynthetic OW--40Oil PolarisSynthetic GearcaseLube DHF 0W/40 PolarisU--JointLube U--Joint AGL
PremiumAllSeasonGrease (3oz.cartridge)(24Count) 2871423 PremiumAllSeasonGrease (14oz.cartridge)(10Count) 2871460 StarterDriveGrease(12Count) 2871515 PremiumU-JointLube(3oz.)(24Count) 2871551 PremiumU-JointLube(14oz.)(10Count) 2871312
2871329
numberinthetableaboveindicatesthenumberof unitsthatareshippedwitheachorder.
POLARISLUBRICANTS/FLUIDSFORSPORTSMAN MODELS
MAINTENANCE 2.7
PurePolarisLubricantsandMaintenanceKitscanbepurch asedatyourlocalPolarisdealer. 2859061 Sportsman500MaintenanceKit --OilFilter&3Qts.of0W--40oil --EBSDriveBelt --PVTCoverSeal --SparkPlug --InstructionSheet 2873554 --Sportsman400/500OilChangeKit
--OilFilter&3Qts.of0W--40oil --ReservoirGasket --DrainPlugGasket --InstructionSheet ATVAngleDriveFluid
MAINTENANCE 2.8 SPORTSMAN400/500COMPONENTLOCATIONS FrontGearcase PVTCover FrontPropShaft (BehindRadiator) (BetweenTransmission andFrontGearcase) FrontDriveShafts RightSideView Engine Recoil Transmission RearStorageCompartment FrontStorage Compartment &Rack GasCap GearShifter BrakeLever Ignition/Key Choke BrakeFluidReservoir InstrumentCluster (Speedometer) LightControl &RunSwitch Reverse Override Throttle AWDSwitch Worklight OilDipstick FuelValve Muffler AuxiliaryBrake
Changeafter1stmonth,6monthsor100 hoursthereafter;Changemoreoften(25-50 hours)inextremelydirtyconditions,orshort tripcoldweatheroperation.
MAINTENANCE 2.9 LUBRICATION Ill. # Item LubeRequired Method Frequency* 1 EngineOil Polaris0W--40 Synthetic(PN 2871567 )
Addoiltoproperlevel,seeprocedure.
2 Transmission AGLGearcaseLubricant(PN2873602 ) Addlubetobottomoffillplughole threads.
© 3 BrakeFluid PolarisDOT3Brake Fluid(PN2870990 ) Fillmastercylinderreservoirtoindi-
4 FrontGearcase PolarisDemand DriveHubFluid(PN 2871654 )
dure.
© 5 BallJoints AllPurposeGrease Locatefittingsandgrease-3 pumpsmaximum Annually © 6 Propshaft Yoke PremiumU-Joint Grease ¢ (PN2871551 ) Locatefittingsandgrease-3 pumpsmaximum Annually ©
©
¢ GreaseconformingtoNLGINo.2,suchasPolarisPremiumAllSeasonGrease,ConocoSuperlubeMor MobilegreaseSpecial 3Transmission 1.EngineOilandFilter 3.BrakeFluid(LefthandMasterCylinder) Dipstick OilFillPlug FillPlug Drain Plug 4.FrontGearcase (CentralizedHilliard) OilFilter 6.PropshaftYoke (3pumpsmax.) 5.HubStrut 0W/40 AGL DHF MasterCylinder Reservoir
Changeannually
catedlevelinsidereservoir. Asrequired.Changefluidevery2years.
Addoiltoproperlevel,seeproce-
Changeannually
NOTE: RefertoPage2.6forthePolarisLubricantIdentificationtable. *Moreoftenundersevereuse,suchasoperatedinwaterorundersevereloads. ¡ Semi-annuallyor50hoursofoperation(refertoMaintenanceScheduleforadditionalinformation) Moreoftenundersevereconditions(operatinginwaterorhaulingheavyloads)
Annuallyor100hoursofoperation(refertoMaintenanceScheduleforadditionalinformation) Moreoftenundersevereconditions(operatinginwaterorhaulingheavyloads)
Thank you very much foryourreading. PleaseClickHere Then Get More Information.
