2004 - 2005 Polaris Atv Sportsman 500 6x6 Complete Service / Repair / Workshop Manual * BEST * PDF 290+ Pages Download!!


SERVICE MANUAL COVERS:
=================

Topics covered in this service manual include:


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


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5. Language: English
6. Pages: 280+


TABLE OF CONTENTS:
==============

These are the exact topics that the 1 2004 - 2005 Polaris Atv Sportsman 500 6x6 Service Manual covers:

Specifications, 1.5
Specifications, 1.4
A
A-Arm Replacement, 1.8
Air Filter Service, 2.22
Alternator Output Test, 10.31
AWD Armature Plate Inspection, 7.8
AWD Magnetic Coil Installation, 7.7
AWD Magnetic Coil Removal, 7.6
AWD Operation, 7.2
B
Battery Charging, 10.33, 10.35, 10.39
Battery Check Before Install, 10.33
Battery Installation, 10.34, 10.37
Battery Maintenance, 2.19, 10.33
Battery Service, 10.32, 10.34, 10.35, 10.36,
10.37, 10.38
Battery Terminal Bolts, 10.36
Battery Testing, 10.34, 10.37
Battery, Off Season Storage, 10.35, 10.38
Body Assembly Exploded View, 1.4
Brake Bleeding, 9.7
Brake Bleeding/Fluid Change, 9.13
Brake Caliper Assembly, Rear, 9.19
Brake Caliper Disassembly, Front, 9.14
Brake Caliper Inspection, Front, 9.15
Brake Caliper Installation, Front, 9.17
Brake Caliper Removal, Front, 9.14
Brake Caliper Removal, Rear, 9.18
Brake Disc Inspection, Front, 9.13
Brake Disc Inspection, Rear, 9.20
Brake Disc Removal/Replacement, Front, 9.13
Brake Fluid Change, 9.7
Brake Fluid Level, 2.32
Brake Hose/Fitting Inspection, 2.33
Brake Light Switch Testing, 10.40
Brake Noise, 9.3
Brake Pad Application, 9.3
Brake Pad Assembly, Front, 9.11
Brake Pad Inspection, 2.33
Brake Pad Installation, Rear, 9.18
Brake Pad Removal, Front, 9.10
Brake Pad Removal, Rear, 9.17
Brake System Inspection, 2.32
Brake System Main Components, 9.6
Brake System Operation, 9.4
Brake System Service Notes, 9.3
Brake, Auxiliary, Hydraulic, 2.33
Brake, Auxiliary, Testing, 2.33
Brakelight Lamp Replacement, 10.40
Breather Filter Maintenance, 2.24
Breather Hose Inspection, 2.24
C
Cam Chain Drive Sprocket Installation, 3.43
Cam Chain Tensioner Inspection, 3.15
Cam Chain Tensioner Installation, 3.49
Cam Chain Tensioner Removal, 3.14
Cam Chain/Camshaft Installation, 3.46
Cam Chain/Tensioner Blade, 3.32
Camber & Caster, 2.29
Camshaft Inspection, 3.18
Camshaft Removal, 3.16
Camshaft Timing, 3.46, 3.48
Carburetor Assembly, 4.9
Carburetor Disassembly, 4.7
Carburetor Exploded View, BST34, 4.2
Carburetor Float Bowl Draining, 2.18
Carburetor Float Height Adjustment, 4.10
Carburetor Float System, 4.7
Carburetor Fuel Level Testing, 4.11
Carburetor Inspection, 4.8, 4.9
Carburetor Main System, 4.7
Carburetor Needle and Seat Testing, 4.10
Carburetor Operation, 4.5
Carburetor Pilot System, 2.16, 4.6
Carburetor Starter System, 4.6
Carburetor System Function, 4.5
CDI Output Test, 10.30
Chain Adjustment -- Middle Axle, 2.34
Chain Adjustment -- 6x6 Rear Axle, 2.34
Charging System Break Even Test, 10.31
Charging System Testing, 10.29
Choke Adjustment, 2.15
Clutch Alignment, 6.15
Clutch Offset, 6.16
Cold Weather Kits, 2.6
Combustion Chamber, 3.23
Compression Release Removal/Inspection, 3.17,
3.18
Compression Test, 2.19
Concentric Swing Arm Installation, 1.10
Concentric Swing Arm Removal, 1.9
Concentric Swingarm Middle Axle Assembly, 7.23
Concentric Swingarm Middle Axle Assembly, Exploded
View, 7.26
Concentric Swingarm Middle Axle Disassembly,
7.22
Concentric Swingarm Middle Axle Installation,
7.24
Concentric Swingarm Middle Axle Removal, 7.21
Concentric Swingarm Middle Housing Removal,
7.27
Controls Inspection, 2.36
Conversion Table, 1.15
Coolant Level Inspection , 2.22
Coolant Strength, 2.21
Coolant Temperature Sensor, Late 2004, 10.24
Cooling System Hoses, 2.21
Cooling System Overview , 2.21
Cooling System Pressure Test, 3.7
Cooling System Test, 2.21
Cooling System, 4--Stroke Bleeding Procedure,
3.6
Counter Balancer Installation, 3.41
Counter Balancer Shaft End Play, 3.40
Counter Balancer Shaft Removal/Inspection, 3.35
Cover/Panel Removal, 1.2
Crankcase Assembly, 3.41
Crankcase Bearing Inspection, 3.37
Crankcase Bearing Installation, 3.38
Crankcase Disassembly, 3.31
Crankcase Inspection, 3.37
Crankcase Installation, 3.41
Crankcase Separation, 3.33
Cranking Output Test, 10.30
Crankshaft End Play Adjustment, 3.38
Crankshaft Removal/Inspection, 3.36
Crankshaft Straightening, 3.10
Current Draw, 10.30
CV Joint Handling Tips, 7.10
CV Shaft Boot, Inspection, 2.35
Cylinder Cleaning, 3.9
Cylinder Head Assembly, 3.26
Cylinder Head Disassembly, 3.21
Cylinder Head Inspection, 3.21
Cylinder Head Installation, 3.46
Cylinder Head Reconditioning, 3.23
Cylinder Head Removal, 3.19, 3.20
Cylinder Head Warpage, 3.21
Cylinder Honing, 3.9
Cylinder Inspection, 3.29
Cylinder Installation, 3.45
Cylinder Removal/Inspection, 3.27
D
Decal Replacement, 1.15
Decimal Equivalents, 1.14
Diagnostic Mode, 2004 Model, 10.6
Diagnostic Mode, 2005 Model, 10.15
Diagnostic Mode, Service Interval, 2005 Model,
10.16
Draining Recoil Housing, 2.24
Drive Belt Removal/Inspection, 6.14
Drive Belt Tension, 6.13
Drive Chain Inspection/Adjustment, 2.34
Drive Clutch Assembly, 6.12
Drive Clutch Bushing Service, 6.16, 6.18, 6.19
Drive Clutch Disassembly, 6.11, 6.12
Drive Clutch Exploded View, 6.7
Drive Clutch Inspection, 6.10
Drive Clutch Operation, 6.2
Drive Shaft Boot Replacement, 7.10
Driven Clutch Assembly, 6.21
Driven Clutch Bushing Service, 6.22, 6.23
Driven Clutch Disassembly, 6.19
Driven Clutch Operation, 6.2, 6.3
Dual Hydraulic Caliper Bleeding, 9.5
Dump Box Exploded View, 1.3
E
Electrical Service Notes, 10.2
Electrical Special tools, 10.2
Engine Accessible Components, 3.8
Engine Assembly, 3.37, 3.38, 3.40, 3.41, 3.42,
3.43, 3.44, 3.45, 3.46, 3.48, 3.49, 3.50
Engine Bottom End Disassembly, 3.27, 3.28,
3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36,
3.37
Engine Break in Period, 3.9
Engine Designation Numbers, 1.2
Engine Exploded View, 3.13
Engine Fastener Torque Patterns, 3.5
Engine Installation Notes, 3.8
Engine Lubrication, 3.10
Engine Mounts, 2.19
Engine Removal, 3.8
Engine Serial Number Location, 1.2
Engine Service Data, 3.3, 3.4
Engine to Frame Ground, 2.20
Engine Top End Disassembly, 3.14, 3.15, 3.16,
3.17, 3.18, 3.19, 3.20, 3.21, 3.22
ETC Operation Test, 10.25
ETC Switch Adjustment, 2.17
ETC Switch Testing, 10.25
Exhaust System, Maintenance, 2.32
Exhaust Valve Adjustment, 2.28, 3.27
F
Fan Control Switch Testing, 10.25
Fan Motor Current Draw Test, 10.24
ECM (Logic Box) Operation, 10.3
Flywheel Identification, 10.26
Flywheel Installation, 3.49
Flywheel Removal/Inspection, 3.32
Frame, Nuts, Bolts, Fasteners, 2.29
Front Axle Installation, 7.9
Front Axle Removal, 7.8
Front Axle Seal Sleeve Replacement, 7.13
Front Drive Axle Exploded View, 7.12
Front Hub Bearing Adjustment, AWD, 7.4
Front Hub Disassembly, 7.3
Front Hub Exploded View, AWD, 7.5
Front Hub Fluid Change, 2.31
Front Hub Fluid Level Inspection, 2.31
Front Hub Seal Replacement, AWD, 7.6
Front Hub/Wheel Bearing Installation, 7.3
Front Prop Shaft Removal, 7.14
Front Strut Assembly, 1.13
Front Strut Ball Joint Replacement, 1.14
Front Strut Weldment Replacement, 1.14
Fuel Filter Maintenance, 2.18
Fuel Pump Exploded View, 4.12
Fuel Pump Service, 4.11
Fuel Tank Assembly, Exploded View, 4.3
G
Gear Circuit Readings, Instrument Cluster, 2005
Model, 10.16
Gear Position Switch Test, 10.4
Gear Shift Boot Replacement, 8.4
Gear Shift Selector Assembly, 8.3
Gear Shift Selector Disassembly, 8.2
Gear Shift Selector Installation, 8.4
Gear Shift Selector Removal, 8.2
Gearcase Assembly, Front, 7.17
Gearcase Disassembly, Front, 7.16, 7.17
Gearcase Exploded View, Front, 7.20
Gearcase Installation, Front, 7.19
Gearcase Lubrication, Front, 2.13
Gearcase Removal, Front, 7.16
Glossary of Terms, 1.16
H
Headlamp Service, 10.40, 10.41
Headlamp Switch Testing, 10.42
Headlight Adjustment, 10.41
High Engine Coolant Temperature, 2004 Model,
10.5
High Engine Coolant Temperature, 2005 Model,
10.14
High/Low Battery Voltage, 2004 Model, 10.5
High/Low Battery Voltage, 2005 Model, 10.15
Hilliard Clutch Disassembly/Inspection, 7.7
Honing to Oversize, 3.9
Hour Meter, 2004 Model, 10.5
I
Idle Speed Adjustment, 2.15
Ignition System Components, 10.27
Ignition System Testing, 10.28
Ignition Timing Curve, 10.2
Instrument Cluster Installation, 10.23
Instrument Cluster Overview, 2005 Model, 10.14
Instrument Cluster Removal, 10.23
Instrument Cluster/Speedometer ID, 10.5
Instrument Cluster Troubleshooting, 2004 Models,
10.5
Intake Valve Adjustment, 2.28
J
Jetting Guidelines, 4.4
K
Keys, Replacement, 1.6
L
Load Test, 10.35, 10.38
Lubricant Symbol I.D. Chart, 2.7
Lubricants, 2.7
Lubricants, Recommended, 2.6
Lubrication Chart, 2.11
Lubrication Charts, 2.9, 2.10
Lubrication, Transmission, 2.12, 8.2
M
MAINTENANCE AND LUBRICATION, 2.3, 2.4,
2.5
Master Cylinder Disassembly, 9.9
Master Cylinder Installation, 9.9
Middle Housing Bearing Service, 7.27
Middle Housing Disassembly, 7.27
Middle Housing Installation, 7.28
Model & Serial Number Location, 1.2
Model Identification, 1.2
O
Odometer, Tachometer,Trip Meter, 2005 Model,
10.14
Oil Check , Engine, 2.25
Oil Filter Change, 2.25
Oil Flow, 3.11, 3.12
Oil Pipes, 3.51
Oil Pressure Test, 3.11
Oil Pump Assembly, 3.35
Oil Pump Installation, 3.41
Oil Pump Priming, 3.11
Oil Pump Priming--Magnum 500, 2.27
Oil Pump Removal/Inspection, 3.34
Oil Pump Shaft End Play, 3.40
One Way Valve, 3.33
One Way Valve Installation, 3.43
Optional Springs, 1.6
P
Paint Codes, 1.6
Periodic Maintenance Chart, 2.3, 2.4, 2.5
Pilot Screw Adjustment, 2.16
Piston Identification, 3.5
Piston Installation, 3.44
Piston Removal, 3.28
Piston Ring Installation, 3.44
Piston Ring Installed Gap, 3.31
Piston to Cylinder Clearance, 3.30
Piston/Rod Inspection, 3.30
Pre-Ride Inspection, 2.6
Programmable Service Interval, 2004 Model,
10.5, 10.6
Programmable Service Interval, Diagnostic Mode,
Intl. Models, 10.14
Publication Numbers, 1.6
Pump Shaft Oil Seal Installation, 3.41
PVT Assembly, 6.6
PVT Disassembly, 6.5
PVT Drying, 6.3
PVT Maintenance, 6.3
PVT Operation, 6.2
PVT Overheating, 6.4
PVT System Sealing/Ducting Components, 6.7
PVT Troubleshooting, 6.25, 6.26
R
Radiator Cap Pressure Test, 3.7
Radiator Coolant Level Inspection, 2.22
Radiator, Maintenance, 2.21
Rear Axle Bend, 7.29
Rear Axle Installation, 7.28
Rear Axle Removal, 7.28
Rear Drive Axle, Exploded View, 7.29
Rear Strut Stabilizer, 1.11
Rear Swing Arm Weldment, 1.12
Recoil Assembly, 3.52
Recoil Disassembly/Inspection, 3.51
Recoil Draining, 2.24
Rocker Arm/Shaft Inspection, 3.15, 3.16
Rocker Shaft/Arm Assembly Installation, 3.50
Troubleshooting, Transmission, 8.10
S
Sediment Tube, Maintenance, 2.24
Shift Linkage Adjustment, 2.14
Shift Weights, 6.9
Side Panel Removal, 1.6
Spark Plug Maintenance, 2.20
Special Tools, 1.7, 1.8, 3.5, 4.4, 6.2, 7.2, 8.2, 9.3
Specifications, 1.3
Specifications, Brake, 9.2
Specifications, Cooling System, 3.7
Specifications, Drive Clutch Spring, 6.8
Specifications, Torque, Brakes, 9.2
Specifications, Torque, Engine, 3.2
Specifications, Torque, Final Drive, 7.2
Specifications, Torque, PVT, 6.2
Specifications, Torque, Standard, 1.13
Specifications, Torque, Suspension, 1.2
Specifications, Torque, Transmission, 8.2
Speedometer Troubleshooting, 2004 Models,
10.8, 10.9, 10.10, 10.11, 10.12, 10.13
Speedometer Troubleshooting, 2005 Model,
10.18, 10.19, 10.20, 10.21, 10.22
Speedometer/Odometer, 2004 Model, 10.5
Spider Removal, 6.11
Starter Assembly, 10.45
Starter Disassembly, 10.43
Starter Drive, 10.46
Starter Drive Installation, 3.50
Starter Drive Removal/Inspection, 3.31
Starter Motor Armature Testing, 10.44
Starter Motor Brush Inspection/Replacement,
10.44
Starter System Test, 10.47
Stator Installation, 3.49
Stator Removal/Inspection, 3.32
Steering Assembly, Exploded View, 1.7
Steering Maintenance, 2.28
Steering Post Assembly, 1.15
Strut Casting Seal Replacement, 7.13
Suspension Preload Adjustment, 2.35
Suspension Special Tools, 1.2
Suspension, Front, Inspection, 2.35
Suspension, Rear, Inspection, 2.35
T
Taillight Lamp Replacement, 10.40
Tap Drill Chart, 1.14
Tensioner Blade Installation, 3.44
Thermostat Installation, 3.50
Throttle Cable Adjustment, 2.17
Throttle Operation, 2.15
Tie Rod Inspection, 2.29
Timing Check Procedure, 10.2
Tire Inspection, 2.37
Tire Pressure, 2.37
Tire Tread Depth, 2.37
Toe Alignment, 2.30
Torque Patterns, Engine, 3.5
Transmission Assembly, 8.7
Transmission Disassembly, 8.5
Transmission Exploded View, 8.9
Transmission I.D. Location, 1.2
Transmission Installation, 8.5
Transmission Linkage Adjustment, 2.13
Transmission Removal, 8.5
Troubleshooting, Brakes, 9.20
Troubleshooting, Cooling System, 3.54
Troubleshooting, Engine, 3.53
Troubleshooting, Fuel System/Carb, 4.13
Troubleshooting, Ignition System, 10.30
Troubleshooting, Spark Plug, 3.53
Troubleshooting, Starter System, 10.42
U
U--Joint Assembly, 7.15
U--Joint Disassembly, 7.15
V
Valve Clearance, 2.27
Valve Guide Removal/Installation, 3.23
Valve Inspection, 3.22
Valve Seal Testing, 3.26
Valve Seat Inspection, 3.23
Valve Seat Reconditioning, 3.23
Vent Line Maintenance, 2.18
VIN Identification, 1.2
Voltage Drop Test, 10.43
Voltage Test Open Circuit, 10.34, 10.37
W
Warning Indications for Rider Information Center,
2004 Model, 10.6
Water Pump Mechanical Seal Installation, 3.42
Water Pump Mechanical Seal Removal, 3.37
Water Pump Mechanical Seal Removal, Engine
Installed, 3.42
Water Pump Shaft Oil Seal, 3.37
Wheel Inspection, 2.36
Wheel Installation, 2.36
Wheel Removal Front or Rear, 2.36


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