Polaris 2005 SPORTSMAN 400 Manuals

Manuals and User Guides for Polaris 2005 SPORTSMAN 400. We have 2 Polaris 2005 SPORTSMAN 400 manuals available for free PDF download: Servise Manual, Owner's Manual For Maintenance And Safety

Polaris 2005 SPORTSMAN 400 Servise Manual

Polaris 2005 SPORTSMAN 400 Servise Manual (312 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 143 MB

Table of Contents

General Maintenance

5
- Table of Contents
  5
- Model Identification
  6
- Serial Number Location
  6
- Publication Numbers
  7
- Replacement Keys
  7
General Information Special Tools

11
- Special Tools
  11
- Standard Torque Specifications
  17
- Conversion Table
  19
- Glossary of Terms
  20
Maintenance

21
- Periodic Maintenance Chart
  22
  - Maintenance and Lubrication
    23
  - Polaris Lubricant Symbol Identification
    26
- Front Gearcase Lubrication
  30
- Transmission Lubrication
  31
- Lubrications Points
  32
  - Throttle Inspection
    33
  - Pilot Screw Adjustment
    35
  - Idle Speed Adjustment
    35
  - Throttle Cable
    36
- Fuel System
  36
  - Fuel Lines
    36
  - Vent Lines
    37
  - Carburetor Draining
    37
- Compression Test
  38
  - Spark Plug
    38
  - Engine Mounts
    38
- Battery Maintenance
  39
  - Liquid Cooling System
    39
  - Cooling System Pressure Test
    40
  - Cooling System Hoses
    40
  - Coolant Level
    40
  - Radiator Coolant Level
    41
- Air Box Sediment Tube Service
  42
- Breather Filter
  43
- Recoil Housing
  43
  - Engine Oil Level
    44
- Oil and Filter Change
  44
  - Oil Pump Priming
    46
- Valve Clearance
  46
  - Camber and Caster
    49
  - Wheel Alignment
    49
  - Toe Alignment
    49
  - Exhaust Pipe
    50
  - Brake System Inspection
    51
  - Brake Pad Inspection
    51
  - Auxiliary Brake Testing
    52
  - Suspension Spring Preload Adjustment
    52
- Controls
  53
  - Front Suspension
    53
  - Torque Table
    53
- Tire Inspection
  54
- Wheel Removal/Installation
  54
  - Tire Pressure
    54
- Warnt Winch Operation
  56
  - Maintenance Schedule
    60
Maintenance Maintenance Schedule

61
- Special Tools
  62
- Torque Specifications
  62
- Engine Service Data
  63
- Cooling System Specifications
  65
- Piston Identification
  65
- Torque Patterns
  65
- Engine Removal
  67
- Water Pump Mechanical Seal Puller
  67
- Engine Installation Notes
  68
  - Cleaning the Cylinder after Honing
    69
  - Crankshaft Straightening
    69
  - Honing to Oversize
    69
  - Engine Lubrication
    70
  - Oil Pressure Test
    70
  - Eh50Pl Oil Flow Diagram
    72
- EH50PL Engine Exploded View
  73
  - Automatic Compression Release Installation
    78
  - Camshaft Inspection
    78
  - Cylinder Head Disassembly
    81
  - Cylinder Head Warpage
    81
  - Valve Inspection
    82
  - Cylinder Head Assembly
    86
  - Valve Sealing Test
    86
- Piston Support Block
  88
  - Cylinder Inspection
    89
  - Crankcase Disassembly
    91
- Flywheel Puller
  92
  - Crankcase Separation
    93
  - One Way Valve
    93
  - Oil Pump
    94
  - Oil Pump Assembly
    95
  - Crankcase Bearing
    97
  - Crankcase Inspection
    97
  - Bearing Installation
    98
  - Crankcase Assembly
    101
  - Water Pump Mechanical Seal Installation
    102
- Water Pump Install Kit
  103
  - Piston Installation
    104
  - Piston Ring Installation
    104
  - Cylinder Installation
    105
  - Thermostat Installation
    110
  - Oil Pipes
    111
  - Recoil Assembly
    112
- Spark Plug Fouling Checklist
  113
- Troubleshooting
  113
- Cooling System
  114
Fuel System/Carburetion

115
- Fuel Flow Diagram
  118
- Fuel Component Overview
  119
- Fuel Sender Remove/Install
  119
- Carburetor Float Adjustment Tool
  120
- Carburetor Jetting
  121
- CV Carburetor System Function (4 Cycle)
  121
- Mikuni Jet Part Numbers
  121
- Assembly, CV Carburetor
  122
- CV Carburetor Operation
  122
  - Float System
    123
  - Main System
    124
  - Carburetor Cleaning
    126
  - Carburetor Inspection
    126
  - Carburetor Assembly
    127
- Fuel Level
  129
- Fuel Pump
  129
- Needle & Seat Leakage Test
  129
- Fuel Pump Disassembly
  130
- Troubleshooting
  131
Table of Contents

133
- Plastic Insert Removal/Install
  134
  - Ball Joint Replacement Tool
    134
- Side Panel Removal
  135
- Foot Well Removal/Install
  136
- Front Cover Removal
  136
- Front Storage Removal/Install
  137
  - Front Storage Installation
    139
- Radiator Screen Removal
  142
- Body Assembly Exploded View
  143
  - Body Rack Exploded View
    144
- Headlight Pod Exploded View
  145
- Handlebar Block Installation Procedure
  146
- A-Arm Replacement
  148
- Rear Suspension Assembly
  149
  - Strut Assembly
    150
- Front Strut Cartridge Replacement
  151
  - Ball Joint Replacement
    151
- Decal Replacement
  152
  - Clutch Puller
    154
    
    Pvt Drying
    155
    
    Pvt Disassembly
    157
    
    Pvt Sealing and Ducting Components
    159
    
    Drive Clutch Spring Specifications
    160
    
    Shift Weights
    161
    
    Shift Weight Inspection
    162
  - Clutch Offset Alignment Tool
    168
  - Clutch Bushing Replacement Tool Kit
    169
  - Clutch Compression Tool
    172
    
    Bushing Service
    174
    
    Ebs Drive Clutch Exploded View
    176
  - Clutch Bushing Replacement Tool Kit
    177
  - Removal and Installation
    178
  - Roller Pin Removal Tool
    190
    
    Final Drive
    191
    
    Front Hub Assembly
    193
    
    Front Hub Disassembly
    193
    
    Awd Front Drive Axle Exploded View
    196
    
    Rear Hub Installation
    208
    
    Rear Hub Disassembly
    209
    
    Rear Hub Assembly
    209
    
    Rear Drive Shaft
    210
- Steering Post Assembly
  152
Transmission

215
- Transmission Mounting
  216
- Backlash Setting Tool
  217
- Special Tools
  217
- Torque Specifications
  217
- Transmission Removal
  217
- Transmission Installation
  219
- Transmission Disassembly
  221
- Transmission Assembly
  228
- Troubleshooting
  234
- Troubleshooting Checklist
  234
- Transmission Exploded View
  235
Brakes

237
- Specifications
  238
- Brake Noise Troubleshooting
  241
- Brake System Service Notes
  241
- Brake Bleeding / Fluid Change
  243
- Hydraulic Caliper Bleeding
  243
- Master Cylinder Installation
  245
- Master Cylinder Removal
  245
- Front Pad Removal
  246
- Front Pad Assembly
  248
- Brake Burnishing
  249
- Front Disc Inspection
  249
  - Front Brake Disc
    249
- Front Caliper Disassembly
  250
- Front Caliper Removal
  250
- Front Caliper Inspection
  251
- Front Caliper Reassembly
  251
- Front Caliper Installation
  252
  - Rear Brake Pad
    254
- Rear Caliper Removal/Inspection
  255
  - Rear Caliper Assembly
    256
  - Rear Brake Disc
    257
- Troubleshooting
  259
Brakes Notes

261
- Timing Light
  262
- ECM Operation
  263
- Electrical Components
  264
  - Diagnostic Mode
    266
  - Speedometer Removal
    269
  - Speedometer Installation
    269
- Speedometer Troubleshooting
  270
- Fan Motor Tests
  275
  - Fan Motor Current Draw
    275
  - Etc Operation Test
    276
- Ignition System Testing Flow Chart
  279
- Ignition System Troubleshooting
  280
  - Alternator Output Test
    281
- Timing Check Procedure
  282
  - Charging System Testing Flow Chart
    283
  - Battery Identification
    284
  - Battery Charging
    285
  - Battery Installation
    286
  - Battery Testing
    286
- Battery Activation/Service
  287
  - Conventional Battery Installation
    288
  - Off Season Storage
    290
  - High Beam Headlight Bulb Replacement
    291
  - Headlamp Switch
    294
- Fuel Sender Test
  295
- Accessory Wire Hookup
  296
- Starter Motor Service
  298
  - Voltage Drop Test
    298
  - Armature Testing
    300
- Starter System Troubleshooting
  298
- Starter Drive
  301
  - Starter System
    302

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Polaris 2005 SPORTSMAN 400 Owner's Manual For Maintenance And Safety

Polaris 2005 SPORTSMAN 400 Owner's Manual For Maintenance And Safety (135 pages)

Polaris 2005 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 7 MB

Table of Contents

Welcome
6
Table of Contents
8
Vehicle Identification Numbers
10
Safety Decals and Locations
11
Safety
11
- Safe Riding Gear
  15
- Know Your Vehicle
  16
- Age Restrictions
  16
- Operator Safety
  16
- Safety Training
  16
- Equipment Modifications
  20
- Engine Electrical Switches
  36
Controls
36
- Throttle Lever
  37
- Light Switches
  38
- Brake Lever
  38
- Master Cylinder
  39
- Parking Brake
  40
- Setting the Parking Brake
  40
- Important Safeguards
  40
- Auxiliary Brake
  41
- Brake Fluid Level
  41
- Fuel Filter
  42
- Fuel Valve
  42
- Fuel Tank
  42
- Belt Life
  43
- Automatic Transmission Gear Selector
  43
- Engaging Front Gearcase
  44
- All-Wheel Drive (Awd) System
  44
Features
44
- Instrument Cluster
  45
- Rider Information Center
  46
- Diagnostic Mode
  48
- Fuel Safety
  50
Operation
50
- Break-In Period
  51
- Pre-Ride Inspection
  52
- Pre-Ride Checklist
  52
- Starting a Cold Engine
  53
- Starting the Engine
  53
- Cold Weather Operation
  54
- Starting a Warm Engine
  54
- Driving Safely
  55
- Hauling Cargo
  55
- Driving Procedures
  57
- Making Turns
  58
- Driving on Slippery Surfaces
  59
- Driving Uphill
  60
- Driving Downhill
  62
- Turning Around on a Hill
  63
- Driving through Water
  64
- Driving over Obstacles
  65
- Driving in Reverse
  66
- Parking on an Incline
  67
- Noise Emission Control System
  68
- Crankcase Emission Control System
  68
- Exhaust Emission Control System
  68
- Electromagnetic Interference
  68
- Spark Arrestor
  68
Emission Control Systems
68
Periodic Maintenance Chart
69
Maintenance and Lubrication
69
- Periodic Maintenance Record
  73
- Lubrication Guide
  74
- Premium 4 Synthetic Lubricant
  75
- Oil Check
  76
- Oil and Filter Change
  77
- Oil Pump Priming
  79
- Oil Change
  81
- Transmission Oil
  81
- Front Gearcase Oil
  82
- Rear Gearcase Oil
  84
- Radiator Coolant Level
  85
- Engine Cooling System
  85
- Cooling System Operation
  86
- Coolant Level
  86
- Steering Assembly
  89
- Toe Alignment
  89
- Side Panel Removal
  90
- Footwell Removal
  90
- Tire Tread Depth
  91
- Front Wheel Hub Tightening
  91
- Wheel Removal
  91
- Wheel Nut Torque Specifications
  92
- Wheel Installation
  92
- Air Filter Service
  93
- Filter Systems
  93
- Headlight Lamp Replacement
  94
- Low Beam Adjustment
  95
- High Beam Adjustment
  95
- Headlight Housing Replacement
  96
- Lower Headlamp Removal / Installation
  97
- Spark Plug Removal and Replacement
  98
- Vehicle Immersion
  99
- Spark Arrestor
  100
- Pvt System
  101
- High Range
  101
- Low Range
  101
- Pvt Drying
  102
- Battery Installation
  104
- Battery Removal
  104
- Battery Storage
  105
- Battery Charging (Sealed Battery)
  105
- Cleaning and Storage
  107
- Cleaning the ATV
  107
- Fluid Levels
  108
- Breather Filter
  108
- Storage Tips
  108
- Transporting the Atv
  111
- Chrome Wheel Care (if Equipped)
  111
- Removing Corrosion
  111
- Camber and Caster
  112
- Rear Spring
  112
Adjustments
112
- Carburetor/Idle Rpm
  113
- Throttle Cable Freeplay
  114
Polaris Products
116
Troubleshooting
117
- Engine Turns Over, Fails to Start
  118
- Engine Pings or Knocks
  118
- Engine Backfires
  119
- Engine Runs Irregularly, Stalls or Misfires
  119
- Engine Overheating
  120
- Engine Stops or Loses Power
  120
Specifications
121
- Clutching Chart
  122
- Jetting Chart
  122
Warranty
129
Engine Oil
131
Index
134

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