Polaris 2005 Sportsman MV7 Manuals

Manuals and User Guides for Polaris 2005 Sportsman MV7. We have 1 Polaris 2005 Sportsman MV7 manual available for free PDF download: Service Manual

Polaris 2005 Sportsman MV7 Service Manual

Polaris 2005 Sportsman MV7 Service Manual (312 pages)

PN 9919963

Brand: Polaris | Category: Offroad Vehicle | Size: 130.4 MB

Table of Contents

Chapter Index

4
- Table of Contents
  4
- Model Identification
  6
- Serial Number Location
  6
- Publications Numbers / Replacement Keys
  7
  - Publication Numbers
    7
  - Paint Codes
    7
- 2005 Sportsman MV
  8
  - Jetting Chart
    9
- Special Tools
  10
- Standard Torque Specifications
  15
- Conversion Table
  16
- Glossary of Terms
  18
Maintenance

19
- Periodic Maintenance Chart
  20
- Maintenance and Lubrication
  21
- General
  22
- Chapter 1 Chapter 3
  35
- Fuel System
  35
  - Fuel Lines
    35
  - Vent Lines
    36
  - Fuel Filter
    36
  - Compression Test
    36
  - Carburetor Draining
    36
  - Battery Maintenance
    37
    
    Engine Mounts
    37
    
    Spark Plug
    38
    
    Liquid Cooling System
    39
    
    Cooling System Hoses
    39
    
    Radiator Coolant Level
    40
    
    Cooling System Pressure Test
    40
  - Breather Filter / Line Inspection
    42
  - Air Box Sediment Tube
    42
  - Recoil Housing
    43
  - PVT Drying & PVT Drain Plug
    44
    
    Oil and Filter Change
    45
    
    Toe Alignment
    48
    
    Exhaust Pipe
    48
    
    Auxiliary Brake Testing
    51
  - Controls
    52
    
    Front Suspension
    52
    
    Rear Suspension
    52
  - Warn ® Winch Operation
    54
  - Tire Inspection
    54
  - Cleaning and Storage
    56
  - Maintenance Schedule
    58
Maintenance Maintenance Schedule

59
- Maintenance
  35
- Engine Exploded Views
  60
  - Top End
    63
  - Accessible Components
    65
- Piston Identification
  65
- Special Tools
  65
- Torque Specifications
  66
- Engine Fastener Torque Patterns
  67
- 600 Engine Service Data
  68
- Cooling System Specifications
  72
- Cooling System Test
  72
- Chapter 5
  74
- Pvt System
  74
  - Engine Installation Notes
    74
  - Oil Flow
    76
  - Rocker Arm/Pushrod Inspection
    77
    
    Cylinder Head Removal
    77
    
    Cylinder Head Warpage
    78
  - Cylinder Head Disassembly/Inspection
    78
  - Valve Inspection
    80
  - Combustion Chamber
    81
  - Valve Seat Reconditioning
    81
  - Cylinder Head Assembly
    83
  - Cylinder Head Reassembly
    83
  - Valve Sealing Test
    84
  - Valve Train Exploded View
    84
  - Engine Head Reassembly
    85
  - Cylinder Removal
    87
  - Valve Lifter Removal/Inspection
    87
  - Piston Removal
    87
  - Cylinder Inspection
    88
  - Piston Ring Installed Gap
    91
  - Starter Bendix Removal/Inspection
    92
  - Flywheel/Stator Removal/Inspection
    93
  - Flywheel/Stator Installation
    93
  - Engine Crankcase Disassembly/Inspection
    95
  - Camshaft Inspection
    103
  - Engine Crankcase Assembly
    104
  - Troubleshooting
    116
Table of Contents

119
- Fuel Flow Diagram
  122
- Carburetor Jetting
  123
  - Mikuni Jet Part Numbers
    123
  - Jetting Guidelines
    123
- Assembly, CV Carburetor
  124
  - Float System
    126
  - Main System
    126
  - Carburetor Inspection
    128
  - Carburetor Cleaning
    128
  - Carburetor Assembly
    129
- CV Carburetor System Function (4 Cycle)
  124
- Needle & Seat Leakage Test
  130
- Fuel Level
  131
- Fuel Pump Service
  131
  - Fuel Pump Disassembly
    131
- Fuel Sender Service
  132
- Troubleshooting
  132
Fuel System / Carburetion Notes

135
- Plastic Insert Removal/Install
  136
- Side Panel Removal
  137
- Front Cover Removal/Install
  138
- Front Rack/Brushguard Removal/Install
  140
- Rear Rack/Brushguard Removal/Install
  143
- Warn ® Winch Removal/Installation
  144
- Headlight Pod Exploded View
  147
- Handlebar Block Installation Procedure
  148
- Body Assembly Exploded View
  149
- A-Arm Replacement
  153
- Rear Suspension Assembly
  154
  - Strut Assembly
    155
- Front Strut Cartridge Replacement
  156
  - Ball Joint Replacement
    156
- Decal Replacement
  157
- Steering Post Assembly
  157
Clutch

159
- Drive Clutch Exploded View
  160
- PVT Sealing and Ducting Components
  160
- PVT Operation Overview
  161
  - Pvt Drying
    162
- PVT Overheating/Diagnosis
  163
- PVT Cover Removal/Install
  164
- PVT Disassembly
  165
- PVT Assembly/Inspection
  166
  - Drive Clutch Spring Specifications
    167
- Shift Weights /Inspection
  168
  - Shift Weight Inspection
    169
  - Drive Clutch
    169
- Drive Clutch Reassembly
  171
- Drive Belt Removal/Inspection
  172
- Clutch Alignment/Offset
  174
  - Clutch Offset
    175
  - Drive Clutch Inspection
    175
  - Moveable Sheave Bushing Inspection
    176
- Drive Belt Installation
  174
- Driven Clutch Disassembly/Assembly
  177
  - Removal and Installation
    184
- Troubleshooting
  185
Final Drive

187
- Front Hub Assembly
  191
- Front Hub Disassembly
  191
- Awd Front Drive Axle Exploded View
  194
- Rear Hub Installation
  206
- Rear Hub Assembly
  207
- Rear Hub Disassembly/Assembly
  207
- Rear Drive Shaft Removal
  208
- Rear Driveshaft Installation
  209
- Rear Driveshaft Service
  210
- Rear Gearcase Service
  212
- Rear Gearcase Installation
  215
Transmission

217
- Transmission Exploded View
  218
- Transmission
  220
  - Torque Specifications/Lubrication
    220
  - Gear Shift Selector Removal
    220
  - Transmission Removal
    220
  - Transmission Installation
    221
  - Transmission Disassembly
    222
  - Transmission Reassembly
    227
Brakes

233
- Brake System Components
  235
- Front Caliper Exploded View
  236
- Rear Caliper Exploded View
  236
- Brake Noise Troubleshooting
  237
- Brake System Service Notes
  237
- Hydraulic Brake System Overview
  238
- Brake Bleeding / Fluid Change
  239
- Hydraulic Caliper Bleeding
  239
- Master Cylinder Installation
  241
- Master Cylinder Removal
  241
- Front Pad Removal
  242
- Front Pad Assembly
  244
- Brake Burnishing
  245
- Front Disc Inspection
  245
- Front Disc Removal/Replacement
  245
- Front Caliper Disassembly
  246
- Front Caliper Removal
  246
- Front Caliper Inspection
  247
- Front Caliper Reassembly
  247
- Front Caliper Installation
  248
- Rear Pad Removal
  249
- Rear Pad Installation
  250
- Rear Caliper Reassembly
  251
  - Rear Caliper Assembly
    252
- Rear Caliper Removal/Inspection
  251
- Rear Disc Inspection
  253
- Troubleshooting
  255
Brakes Notes

257
- Chapter 9
  257
- Electrical
  257
- Gear Position Switch Test
  258
- Trigger Coil Gap Procedure
  258
- ECM Operation / Overview
  259
- Instrument Cluster Overview
  260
  - Diagnostic Mode
    262
- Speedometer Removal/Installation
  264
- Speedometer Operation Troubleshooting
  266
  - Fan Motor Current Draw
    272
  - Etc Operation Test
    273
- Flywheel Identification
  274
- Ignition System Testing Flow Chart
  276
- Ignition System Troubleshooting
  277
  - Alternator Output Test
    279
  - Charging System Testing Flow Chart
    280
- Battery Identification
  281
  - Load Test
    283
  - Charging Procedure
    284
  - Battery Charging
    285
  - Battery Testing
    286
  - Low Maintenance Battery Installation
    286
  - Battery Load Test
    286
  - Low Maintenance Battery Charging
    287
  - High Beam Headlight Bulb Replacement
    288
  - Fuel Sender Test
    292
  - Starter Motor Removal
    295
  - Voltage Drop Test
    295
  - Armature Testing
    297
  - Starter Drive
    299
  - Starter System Testing Flow Chart
    301

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