Polaris 2004-2005 Sportsman 6x6 Manuals

Manuals and User Guides for Polaris 2004-2005 Sportsman 6x6. We have 1 Polaris 2004-2005 Sportsman 6x6 manual available for free PDF download: Service Manual

Polaris 2004-2005 Sportsman 6x6 Service Manual

Polaris 2004-2005 Sportsman 6x6 Service Manual (289 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 117.04 MB

Table of Contents

General Maintenance

5
- Table of Contents
  5
- Model Identification
  6
- Serial Number Location
  6
- Optional Springs
  10
- Publication Numbers
  10
  - Paint Codes
    10
- Replacement Keys
  10
- Special Tools
  11
- Standard Torque Specifications
  17
  - Conversion Table
    19
- Glossary of Terms
  20
Maintenance

21
- Periodic Maintenance Chart
  22
  - Maintenance and Lubrication
    23
- Pre-Ride Inspection
  26
- Transmission Lubrication
  32
- Front Gearcase Lubrication
  33
  - Idle Speed Adjustment
    35
- Fuel System
  37
  - Throttle Cable
    37
  - Fuel Lines
    38
  - Carburetor Draining
    38
  - Vent Lines
    38
  - Fuel Filter
    38
- Battery Maintenance
  39
  - Engine Mounts
    39
  - Spark Plug
    40
  - Ignition Timing
    40
  - Liquid Cooling System
    41
  - Cooling System Hoses
    41
  - Cooling System Pressure Test
    41
  - Coolant Level
    42
  - Radiator Coolant Level
    42
- Compression Test
  39
- Air Box Sediment Tube Service
  44
  - Breather Hose
    44
- Breather Filter
  44
- Recoil Housing
  44
- Engine Oil Service
  45
  - Oil and Filter Change
    45
- Valve Clearance / Adjustment
  47
- Steering
  48
  - Camber and Caster
    49
  - Wheel Alignment
    50
  - Toe Alignment
    50
  - Exhaust Pipe
    52
- Brake System Inspection
  52
  - Brake Pad Inspection
    53
  - Auxiliary Brake Testing
    53
- Drive Chain Service
  54
  - Front Suspension
    55
  - Suspension Spring Preload Adjustment
    55
- Wheel Removal/Installation
  56
  - Torque Table
    56
  - Tire Pressure
    57
- Tire Inspection
  57
Maintenance Notes

59
- Torque Specifications
  60
- Piston Identification
  63
- Special Tools
  63
- Torque Patterns
  63
- Cooling System Bleeding Procedure
  64
  - Accessible Components
    66
- Engine Installation Notes
  66
  - Honing to Oversize
    67
  - Cleaning the Cylinder after Honing
    67
  - Crankshaft Straightening
    68
  - Engine Lubrication
    68
  - Oil Pressure Test
    69
  - Eh50Pl Oil Flow Diagram
    70
- Engine Removal
  66
- EH50PL Engine Exploded Views
  71
  - Engine Disassembly
    72
  - Camshaft Inspection
    76
  - Automatic Compression Release Installation
    76
  - Cylinder Head Removal
    77
  - Valve Inspection
    80
  - Combustion Chamber
    81
  - Valve Seat
    81
  - Cylinder Head Assembly
    84
  - Valve Sealing Test
    84
  - Cylinder Inspection
    87
  - Crankcase Separation
    91
  - Oil Pump
    92
  - Oil Pump Assembly
    93
  - Crankcase Bearing
    95
  - Crankcase Inspection
    95
  - Bearing Installation
    96
  - Crankcase Assembly
    99
  - Water Pump Mechanical Seal Installation
    100
  - Piston Ring Installation
    102
  - Piston Installation
    102
  - Cylinder Installation
    103
  - Thermostat Installation
    108
  - Oil Pipes
    109
  - Recoil Assembly
    110
- Spark Plug Fouling Checklist
  111
- Troubleshooting
  111
Table of Contents

113
- Fuel Flow Diagram
  115
- Carburetor Jetting
  116
  - Mikuni Jet Part Numbers
    116
  - Jetting Guidelines
    116
- Assembly, CV Carburetor
  117
  - Float System
    119
  - Main System
    119
  - Carburetor Cleaning
    120
- CV Carburetor System Function (4 Cycle)
  117
- Needle & Seat Leakage Test
  122
- Fuel Level
  123
- Fuel Pump Service
  123
  - Fuel Pump Disassembly
    123
- Fuel Pump Exploded View
  124
- Troubleshooting
  125
General Information Notes

127
- Cover/Panel Removal
  128
- Dump Box Exploded View
  129
- Body Assembly Exploded View
  130
- Headlight Pod Exploded View
  131
- Side Panel Removal
  132
- Steering Assembly, Exploded View
  133
- A-Arm Replacement
  134
- Concentric Swing Arm Removal
  135
- Concentric Swing Arm Assembly/Installation
  136
- Rear Swing Arm Weldment
  138
  - Strut Assembly
    139
- Front Strut Cartridge Replacement
  140
  - Ball Joint Replacement
    140
- Decal Replacement
  141
- Steering Post Assembly
  141
Clutch

143
- Driven Clutch Operation
  144
- PVT Maintenance/Inspection
  145
  - Pvt Drying
    145
- PVT Disassembly
  147
- PVT Assembly
  148
- Drive Clutch Exploded View
  149
  - Drive Clutch Spring Specifications
    150
- PVT Sealing and Ducting Components
  149
- Shift Weights
  151
  - Shift Weight Inspection
    152
  - Drive Clutch
    153
  - Spider Removal
    153
- Drive Clutch Assembly
  154
- Drive Belt Tension
  155
- Drive Belt Removal/Inspection
  156
- Drive Belt Installation
  157
  - Clutch Alignment
    157
- Drive Clutch Bushing Service
  158
  - Clutch Offset
    158
- Driven Clutch Disassembly/Inspection
  161
- Driven Clutch Assembly
  163
- Troubleshooting
  167
Table of Contents

169
- AWD Operation Overview
  170
- AWD Front Hub Bearing Adjustment
  172
- AWD Front Hub Exploded View
  173
- AWD Hub Seal Replacement
  174
- AWD Armature Plate Inspection
  176
- AWD Front Drive Axle Removal
  176
- AWD Front Drive Axle Installation
  177
- AWD Front Drive Axle Exploded View
  180
  - Bearing Replacement
    181
- AWD Front Prop Shaft Removal
  182
- U-Joint Assembly
  183
- U-Joint Disassembly
  183
- AWD Front Housing Removal
  184
- AWD Front Housing Assembly
  185
- AWD Front Housing Disassembly
  185
- AWD Front Housing Exploded View
  188
- Middle Axle Removal
  189
- Middle Axle Disassembly
  190
- Middle Axle Assembly
  191
- Middle Axle Installation
  192
- Middle Housing Removal
  195
- Middle Housing Service
  195
- Rear Axle Installation
  196
- Rear Axle Removal
  196
Transmission

199
- Gear Shift Selector Disassembly
  200
- Gear Shift Selector Removal
  200
- Gear Shift Selector Assembly
  201
- Boot Replacement
  202
  - Transmission Removal
    203
- Gear Shift Selector Installation
  202
- Transmission Disassembly
  203
  - Transmission Installation
    203
- Transmission Assembly
  205
- Troubleshooting
  208
  - Troubleshooting Checklist
    208
Table of Contents

209
- Specifications
  210
- Brake Noise Troubleshooting
  211
- Brake System Service Notes
  211
- Special Tools
  211
- Hydraulic Brake System Operation
  212
- Dual Hydraulic Caliper Bleeding
  213
- Brake System Main Components
  214
- Fluid Replacement/Bleeding Procedure
  215
- Master Cylinder Disassembly
  217
- Master Cylinder Installation
  217
- Front Pad Removal
  218
  - Front Pad Assembly
    219
- Brake Pad Burnishing Procedure
  221
- Front Disc Inspection
  221
  - Front Brake Disc
    221
- Front Caliper Disassembly
  222
- Front Caliper Removal
  222
- Front Caliper Inspection
  223
- Front Caliper Assembly
  224
- Front Caliper Installation
  225
- Rear Caliper Removal/Inspection
  226
  - Rear Brake Pad
    226
- Rear Caliper Assembly
  227
- Troubleshooting
  228
  - Rear Brake Disc
    228
Table of Contents

229
- Electrical Service Notes
  230
- ECM Operation
  231
  - Gear Position Indicator
    232
  - Diagnostic Mode
    243
  - Fan Motor Current Draw
    252
  - Etc Operation Test
    253
- Flywheel Identification
  254
- Ignition System Testing Flow Chart
  256
- Charging System Testing Flow Chart
  257
- Ignition System Troubleshooting
  258
  - Alternator Output Test
    259
  - Battery Identification
    260
  - Battery Charging
    261
  - Battery Installation
    262
  - Battery Testing
    262
  - Battery Load Test
    263
- Starter Troubleshooting / Voltage Test
  265
  - Off Season Storage
    266
  - Load Test
    266
  - Brake Light Switch
    268
  - Headlamp Switch
    270
  - Voltage Drop Test
    271
  - Starter Motor
    271
  - Armature Testing
    272
- Starter Drive
  274
- Starter System Testing Flow Chart
  275

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