Torque Patterns; Piston Identification; Cooling System Specifications - Polaris 2005 SPORTSMAN 500 Servise Manual

ENGINE FASTENER TORQUE
PATTERNS
Tighten cylinder head, cylinder base, and crankcase
fasteners in 3 steps following the sequence outlined
below.
3 2
1 4
Cylinder Head
Cylinder Base
Pattern
7
5
3
1
2
4
Crankcase
Pattern

PISTON IDENTIFICATION

The piston may have an identification mark or the
piston may not have an identification mark for
piston placement. If the piston has an identification
mark, follow the directions for piston placement
below. If the piston does not have an identification
mark, the direction for placement of the piston does
not matter.
Note the directional and identification marks when
viewing the pistons from the top. The letter "F", " !
", " "" or : must always be toward the flywheel side
of the engine. The other numbers are used for
identification as to diameter, length and design. Four
stroke engine rings are rectangular profile. See text
for oil control ring upper rail installation. Use the
information below to identify pistons and rings.
6mm
5
6
9
10
8
6
Engine Oversize
Model
Available*
No.
(mm)
EH50PLE .25
.50
EH42PLE 25
.50
*Pistons and rings marked 25 equal .25mm (.010I)
oversized
Pistons and rings marked 50 equal .50mm (.020I)
oversized
COOLING SYSTEM
SPECIFICATIONS
THERMISTOR READING DURING OPERATION
Condition Approx. Reading
(Min- -Max)
Hot Light 178Ω -- 190Ω
On
Fan Off 296Ω -- 316Ω
Fan On 236Ω -- 251Ω
System
Capacity
Radiator
Cap Relief
Pressure
ENGINE
Piston Standard
Length Piston Iden-
tification
72 mm C
B
66 mm
Thermistor
26 ± 2.1 ft.lbs.
(35 ± 3 Nm)
Temperature
215° F
(102° C)
180° F (82° C)
195° F (91° C)
2.25 Quarts
(2.13L)
13 PSI
3.5