Polaris 2004-2005 Sportsman 6x6 Service Manual page 8

2004 SPORTSMAN 500 6x6
MODEL: . . . . . . . . . .
MODEL NUMBER: . A04CL50AA
ENGINE MODEL: . . EH500PLE104
Engine
Platform
Engine Model Number
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Compression Ratio
Compression Pressure
Engine Idle Speed
Cooling System/Capacity
Overheat Warning
Lubrication
Oil Requirements
Exhaust System
Carburetion
Carburetor model
Main Jet
Pilot Air Jet
Jet Needle- -clip position
Needle Jet
Pilot Screw
Float Height
Fuel Delivery/Tank Capacity
Fuel Capacity / Requirement
Electrical
Alternator Output
Voltage Regulator
Lights : High Beam
Low Beam
Brake
Tail
Ignition System
Ignition Timing
Spark plug / Gap
Battery / Model / Amp Hr
Circuit Breakers
Starting
Instrument Cluster
1.4
Fuji 4 stroke, Single Cylinder
EH500PLE104
499cc
1
92 x 75 mm
10:2
50- -90 psi
1200 ± 200 Rpm
Liquid / 2.25 qts. (2.1 L)
HOT on Instrument Cluster
Pressurized Dry Sump
Polaris 0W- -40
Single Pipe
Mikuni BST 34mm
142.5
160
4HB41- -3
Q- -4M (829)
3 Turns Out
13 ± 1 mm (0.51 ± 0.40")
Fuel Pump
4.25 gal. (16.09L)
87 Octane (minimum)
89 Oxygenated
250 w @ 5000 RPM
3- -Phase
50 watts
27 watts
26.9 watts
8.26 watts
DC/CDI Ignition
30° ± 2° BTDC @ 5000 RPM
NGK BKR5E/ .036 in./ 0.9 mm
Sealed Low Maintenance - -
14 Amp Hr
Solid State in ECM
Electric / Recoil Backup
LCD
GENERAL INFORMATION
Drivetrain
Transmission Type
Transmission Fluid Capacity
Front Gearcase Capacity
Front Hub Capacity
Gear Ratio : Low
High
Rev.
Final
Clutch Type
Belt
Steering / Suspension
Front Suspension / Shock
Front Travel
Rear Suspension
Style / Shock
Rear Travel
Ground Clearance
Shock Preload Adjustment
Front / Rear
Turning Radius
Toe Out
Wheels / Brakes
Wheel Size - - Front
Wheel Size - - Center / Rear
Air Press. F/R Tires
Brake - - Front
Brake - - Rear
Brake Fluid
JETTING CHART
AMBIENT TEMPERATURE
Below 40°F
Altitude
Below 5°C
0--1800
Meters
(0--6000)
(Feet)
above 1800
(above 6000)
CLUTCH CHART
Shift
Weight
Altitude
10 MH
0--1800
(5630513)
(0--6000)
Meters
(Feet)
1800--3700
10 WH
(6000--12000) (5630710)
H- -Pattern H/L/N/R
32 oz.
4 oz. (120 ml)
2.5 oz. (75 ml)
6.69/1
3.34/1
5.17/1
12/38 80 P chain
PVT
3211077
A- -arm / MacPherson Strut
6.7 in. / 17.02 cm
Progressive Rate Single
Center 6.5 in. / 16.5 cm
Rear 7.5 in / 19.1 cm
5.5 in. / 14 cm
F - -Spring tension - - Std.
R - - Cam Adjustment
119 in. / 302 cm unloaded
0 - - 1/16 in / .0 - - .159 mm
25 x 8 - - 12 / 4- -156
25 x 11 - - 10 / 4- -156
5 psi Front / 5 psi Rear
Dual Hydraulic Disc
Hydraulic Disc
Polaris DOT 3 Brake Fluid
Above 40°F
Above 5°C
147.5 142.5
140
135
Drive
Driven Driven
Helix
Spring
Spring
40°
Blu/Grn Red
(5131446)
(7041157) (7041198)
2- -2
40°
Blu/Grn
Red
(5131446)
(7041157) (7041198)
2- -2