2005 Polaris Sportsman 400/500 ATV Repair manual

SPORTSMAN 400/500 99194 9919425

2005 SPORTSMAN 400/500 SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 2005 Polaris Sportsman ATVs. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340. 2005 Sportsman 400/500 ATV Service Manual (PN 9919425) ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of the Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustries.com or purchased from www.purepolaris.com or contact your nearest Polaris dealer.

GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Location 1.2 ................... Publication Numbers 1.3 ..................... Paint Codes 1.3 ............................. Replacement Keys 1.3 ....................... General Specifications - Sportsman 400/500 1.4-1.6 . Special Tools 1.7--1.12 ............................ Standard Torque Specifications 1.13 ............ Decimal Equivalent Chart 1.14 ................. Conversion Table 1.15 ........................ Glossary of Terms 1.16 ........................ Specs

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 05 MH 50 AA Model Option ENGINE DESIGNATION NUMBERS 42 EH42PLE Single, L/C, SOHC 4 Stroke, Electric Start ............... 50 EH50PLE Single, L/C, SOHC 4 Stroke, Electric Start ............... VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A M H 5 0 A * 5 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow. MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION Engine model number is on recoil housing (A). The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is lo- cated on top of the transmission snorkel, right side of machine.

GENERAL INFORMATION 1.3 PUBLICATION NUMBERS Year Model Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2005 Sportsman 400 9919412 9919413 9919414 2005 Sportsman 500 9919412 9919416 9919417 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com ATV PAINT INFORMA TION FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. COLD WEATHER KITS FOR 4 CYCLE A TVS Engine Heater -- (PN 2871507) ACCESSORY ENGINE HEATER REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 31XX Key Series Number

GENERAL INFORMATION 1.4 MODEL: 2005 Sportsman 400 .......... MODEL NUMBER: A05MH42 . ENGINE MODEL: 425 .. Category Dimension Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 51 in./129.5 cm Ground Clearance 11 in./27.94 cm Dry Weight 703 lbs./319 kg Gross Vehicle Weight 1210 lbs./549 kg Oil Capacity 2.25 qts./2.1 ltr Coolant Capacity 2.25 qts./2.1 ltr Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Hitch Tongue Weight 120 lbs./54.4 kg Body Style SPIRIT MODEL: 2005 Sportsman 500 .......... MODEL NUMBER: A05MH50 . ENGINE MODEL: 500 .. Category Dimension Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 51 in./129.5 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1222 lbs./554 kg Oil Capacity 2.25 qts./2.1 ltr Coolant Capacity 2.25 qts./2.1 ltr Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Hitch Tongue Weight 120 lbs./54.4 kg Body Style SPIRIT

GENERAL INFORMATION 1.5 MODEL: 2005 SPORTSMAN 400 .......... MODEL NUMBER: A05MH42AB, AG, AH . ENGINE MODEL: EH42PLE .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number EH42PLE05 Engine Displacement 425cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 70 mm Compression Ratio 9.2:1 Compression Pressure 50--90 psi Engine Idle Speed 1100 ± 200 Rpm Cooling System/Capacity Liquid / 2.25 qts. (2.1 L) Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements Polaris 0W--40 Exhaust System Single Pipe Carburetion Carburetor model Mikuni BST 34mm Main Jet 172.5 Pilot Jet 40 Jet Needle 4GAC33--3 Needle Jet Q--0(829) Pilot Screw 2.75 Turns Out Pilot Air Jet 160 Float Height 13 ± 1 mm (0.51 ± 0.40“) Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal. (19.9L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 240 w @ 3000 RPM Voltage Regulator 3--Phase -- Sure Power Lights : High Beam 50 watts Low Beam 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 12 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Circuit Protection Solid State Spark plug / Gap NGK BKR5E/ .036 in./ 0.9 mm Battery / Model / Amp Hr Maintenance--Free -- 12 Amp Hr Starting Electric / Recoil Backup Instrument Cluster LCD Drivetrain Transmission Type Drum Shift H/L/N/R/P Transmission Capacity 32 oz. Front Gearcase Capacity 5 oz. (147.8 ml) Gear Ratio : Low High Rev. Final 23.91 / 1 10.49 / 1 16.30 / 1 3.82 / 1 Clutch Type PVT Non EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension Style / Shock Progressive Rate Independent w/ Two x 2” Coil--over shocks Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Spring tension -- Std. Turning Radius 65 in. / 165.10 cm Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel/Tire Size -- Front 25x 8 -- 12/ 4--156 Wheel/Tire Size -- Rear 25x 11 -- 12/ 4--156 Air Press. F/R Tires 5 psi Front / 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc Brake Fluid Polaris DOT 3 Brake Fluid JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 177.5 172.5 170 165 CLUTCH CHART Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10 WH 20--40 34--38° Second Spring Black (5630710) (5631356) (7041782) (5133920) (7041782) (7041157) (7042202) 34--38° (5133920) Black Blu/Grey Blu/Grn Driven Helix Position: 2--2

GENERAL INFORMATION 1.6 MODEL: 2005 SPORTSMAN 500 .......... MODEL NUMBER: A05MH50AB, AC, AG, AH . ENGINE MODEL: EH50PLE .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number EH50PLE13 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10:2 Compression Pressure 50--90 psi Engine Idle Speed 1100 ± 200 Rpm Cooling System/Capacity Liquid / 2.25 qts. (2.1 L) Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements Polaris 0W--40 Exhaust System Single Pipe Carburetion Carburetor model Mikuni BST 40mm Main Jet 155 Pilot Jet 40 Jet Needle 6MGH1--94--3 Needle Jet X--6M Pilot Screw 2 Turns Out Pilot Air Jet 160 Float Height 14.7 ± 1 mm (0.58 ± 0.40“) Fuel Delivery/Tank Capacity Fuel Pump Fuel Capacity / Requirement 4.25 gal. (19.9L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 240 w @ 3000 RPM Voltage Regulator 3--Phase -- Sure Power Lights : High Beam 50 watts Low Beam 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 12 watts Circuit Protection Solid State Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E/ .036 in./ 0.9 mm Battery / Model / Amp Hr Maintenance--Free -- 12 Amp Hr Starting Electric / Recoil Backup Instrument Cluster LCD Drivetrain Transmission Type Drum Shift H/L/N/R/P Transmission Fluid Capacity 32 oz. Front Gearcase Capacity 5 oz. (147.8 ml) Gear Ratio : Low High Rev. Final 23.91 / 1 10.49 / 1 16.3 / 1 3.82 / 1 Clutch Type PVT w/EBS Belt 3211095 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension Style / Shock Progressive Rate Independent Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Spring tension -- Std. Turning Radius 65 in. / 165.10 cm Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size -- Front 25x 8 -- 12/ 4--156 Wheel Size -- Rear 25x 11 -- 12/ 4--156 Air Press. F/R Tires 5 psi Front / 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc Brake Fluid Polaris DOT 3 Brake Fluid JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 160 155 152.5 147.5 CLUTCH CHART Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10 WH 10 RH EBS 41--37° Second Spring Wht/Yel (5630710) (5630709) (7041635) (5131674) (7041635) (7041157) (7041157) Wht/Yel (5131674) Blu/Grn Blu/Grn EBS 41--37° * EBS models require no helix / spring adjustment

2005 Polaris Sportsman 400/500 ATV Repair manual

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