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.