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Polaris Manuals
Offroad Vehicle
2005 SPORTSMAN 500
Servise manual
Torque Specifications; Special Tools - Polaris 2005 SPORTSMAN 500 Servise Manual
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Also See for 2005 SPORTSMAN 500
:
Owner's manual for maintenance and safety
(135 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
ENGINE
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Fastener
Size
Blind Plug (Oil
1/8 PT
Pressure)
(28tpi)
Camshaft Sprocket
6mm
Camshaft Chain
6mm
Tensioner Lever
Camshaft Chain
6mm
Tensioner
Camshaft Chain
11mm
Tensioner Cap
Carburetor Adaptor
8mm
Crankcase
8mm
Crankshaft Slotted
28mm
Nut (Cam Chain
Drive Sprocket)
Cylinder Base
10mm
Bolts
6mm
Cylinder Head
11mm
Bolts
6mm
Drive Clutch Bolt
7/16 -
Flywheel
16mm
Oil Delivery Pipe
12mm
Oil Drain Bolt
14mm
(Crankcase)
Oil Filter Pipe Fit-
20mm
ting
Oil Hose Fitting
1/8 Pipe
Thread
Hard Metal Oil Line
Banjo Fitting
Oil Pump
6mm
Oil Pump Case
5mm
Screw
One Way Valve
11mm
Recoil Housing
6mm
Rocker Cover
6mm
Rocker Support
8mm
Rocker Adjuster
6mm
Screw
Water Pump Impel-
6mm
ler Nut
3.2
EH42PLE/
EH50PLE
Ft. Lbs. (Nm)
6.5-11 (9-15 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
14-19 (20-25 Nm)
12-14 (16-20 Nm)
14-15 (19-21 Nm)
35-51 (47-69 Nm)
45-49 (61-67 Nm)
6-8 (9-11 Nm)
Refer to Engine
Assembly for
torque procedure
40 (55 Nm)
20
58-72 (78-98 Nm)
11-15 (15-21 Nm)
14-17 (19-23 Nm)
36-43 (49-59 Nm)
6.5-11 (9-15 Nm)
N/A
11--16 ft.lbs.
(15--21 Nm)
5-6.5 (7-9 Nm)
1.5-2 (2-3 Nm)
14-19 (20-25 Nm)
5-6.5 (7-9 Nm)
7-8 (9-11 Nm)
8-10 (11-13 Nm)
6-7 (8-10 Nm)
5-6.5 (7-9 Nm)
Water Pump
6mm
Housing Cover
Stator Plate
6mm
Starter Motor
6mm
Spark Plug
14mm
Thermistor
----
SPECIAL TOOLS
PART NUMBER
2200634
2870390
2871043
2871283
5131135
2870569
2870975
PV- -43527
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
9-11 (12-15 Nm)
26 ± 2.1 (35 ± 3
Nm)
TOOL
DESCRIPTION
Valve Seat
Reconditioning Kit
Piston Support
Block
Flywheel Puller
Crankshaft/Water
Pump Seal Install
Kit
Water Pump
Install Kit
Crankshaft Truing
Stand
Mity Vact
Pressure Test Tool
OIl Filter Wrench
Table of
Contents
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Chapters
General Maintenance
5
General Information Special Tools
11
Maintenance
21
Maintenance Maintenance Schedule
61
Fuel System/Carburetion
115
Table of Contents
133
Transmission
215
Brakes
237
Brakes Notes
261
Table of Contents
Troubleshooting
Spark Plug Fouling Checklist
113
Troubleshooting
131
Troubleshooting
234
Brake System Service Notes
241
Troubleshooting
259
Speedometer Troubleshooting
270
Ignition System Troubleshooting
280
Starter System Troubleshooting
298
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This manual is also suitable for:
2005 sportsman 400
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