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( 2005 POLARIS ATV SPORTSMAN 700 EFI ) & ( 2005 POLARIS SPORTSMAN 800 EFI ) - DIY FACTORY SERVICE / REPAIR MANUAL - 05 TWIN DOWNLOAD +
About this manual
( 2005 POLARIS ATV SPORTSMAN 700 EFI ) & ( 2005 POLARIS SPORTSMAN 800 EFI ) - * DII (DO-IT-YOURSELF) FACTORY SERVICE / REPAIR / MAINTENANCE MANUAL - DOWNLOAD!!
( VERY HIGH QUALITY FACTORY SERVICE MANUAL - 117+ MB !! )
1. File Format: PDF
2. Language: English
3. Downloadable: YES
4. Compatible: All Versions of Windows & Mac
5. Requirements: Adobe PDF Reader & WinZip.
DESCRIPTION:
=========
COVERS ALL MODELS & ALL REPAIRS A-Z
THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.
COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!
YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE CD-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.
ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES!
FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.
ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!
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SERVICE MANUAL COVERS:
===================
( JUST A PART OF THE FULL TABLE OF CONTENTS / INDEX SHOWN HERE ...)
GENERAL
MAINTENANCE
ENGINE
ELECTRONIC FUEL INJECTION
CLUTCHING
FINAL DRIVE
BODY AND STEERING
TRANSMISSION
BRAKES
ELECTRICAL
Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
2005 Sportsman EFI Dimensions . . . . . . . . . . . 1.3
Specifications - Sportsman EFI . . . . . . . . . . . . 1.4--1.5
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.6
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.6
Standard Torque Specifications . . . . . . . . . . . . 1.6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7--1.10
Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.13
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.5
Component Locations . . . . . . . . . . . . . . . . . . . . 2.6
Lubricant and Maintenance Product Numbers 2.7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Lubricatin Charts . . . . . . . . . . . . . . . . . . . . . . . . 2.9-2.10
Front & Rear Gearcase Lubricatin . . . . . . . . . 2.11-2.12
Transmission Lubricatin . . . . . . . . . . . . . . . . . . 2.13
Throttle Cable Adjustment . . . . . . . . . . . . . . . . . 2.14
Transmission Linkage Inspection . . . . . . . . . . . 2.15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.15-2.16
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.16-2.17
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Coolant System Maintenance . . . . . . . . . . . . . . 2.18-2.20
Radiator Screen Removal . . . . . . . . . . . . . . . . . 2.20
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.20-2.21
Air Box Sediment Tube Service . . . . . . . . . . . . 2.21
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21-2.22
PVT Drying & PVT Drain Plug . . . . . . . . . . . . . . 2.22
Oil Change/Filter . . . . . . . . . . . . . . . . . . . . . . . . . 2.23-2.24
Steering and Toe Alignment . . . . . . . . . . . . . . . 2.25-2.27
Exhaust System Maintenance . . . . . . . . . . . . . 2.27-2.28
Brake System Service . . . . . . . . . . . . . . . . . . . . 2.28-2.29
Suspension Service . . . . . . . . . . . . . . . . . . . . . . 2.29-2.30
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Wheel/Tire --Removal/Installation/Inspection . 2.31-2.32
Warn® Winch Operation . . . . . . . . . . . . . . . . . . 2.33-2.34
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . 2.35-2.36
800 EFI Exhaust Canister Maintenance . . . . . 2.36
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . 3.2--3.7
Exhaust System View / Notes . . . . . . . . . . . . . . . . . 3.8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Engine Fastener Torque Patterns . . . . . . . . . . . . . 3.11
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . 3.12--3.14
Cooling System Specifications . . . . . . . . . . . . . . . . 3.15
Cooling System Test . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Engine Removal/Installation . . . . . . . . . . . . . . . . . . 3.16--3.17
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . 3.17--3.18
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Rocker Arm/Pushrod Inspection . . . . . . . . . . . . . . . 3.21
Cylinder Head Disassembly/Inspection . . . . . . . . . 3.21--3.23
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . 3.25
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . 3.25--3.27
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . 3.27
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Valve Train Exploded View. . . . . . . . . . . . . . . . . . . . 3.28
Engine Head Reassembly . . . . . . . . . . . . . . . . . . . . 3.29--3.30
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Valve Lifter Removal/Inspection . . . . . . . . . . . . . . . 3.31
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31--3.32
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32--3.33
Piston/Rod/Ring Service . . . . . . . . . . . . . . . . . . . . . 3.33--3.35
Starter Bendix Removal/Inspection . . . . . . . . . . . . 3.36
Flywheel/Stator Removal/Inspection . . . . . . . . . . . 3.37
Flywheel/Stator Installation . . . . . . . . . . . . . . . . . . . 3.37--3.38
Engine Crankcase Disassembly/Inspection . . . . . 3.38--3.46
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Engine Crankcase Assembly . . . . . . . . . . . . . . . . . 3.47--3.58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59--3.60
4--Stroke Coolant System Bleeding Procedure . . 3.61
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
EFI System Exploded View . . . . . . . . . . . . . . . . 4.4--4.5
Fuel Tank Exploded View . . . . . . . . . . . . . . . . . . 4.6
Electronic Fuel Injection System . . . . . . . . . . . 4.7
Operation Overview . . . . . . . . . . . . . 4.7
Initial Start/Priming Procedure . . . . . . 4.7
Electronic Control Unit . . . . . . . . . . . . . . . . . . . 4.8
Service . . . . . . . . . . . . . . . . . . . . . . 4.8
Replacement . . . . . . . . . . . . . . . . . . 4.8
Fuel Pump/Tank Assembly . . . . . . . . . . . . . . . . 4.9
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.9-4.10
Replacement . . . . . . . . . . . . . . . . . . 4.10--4.11
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . 4.11
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Replacement . . . . . . . . . . . . . . . . . . 4.11
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Service . . . . . . . . . . . . . . . . . . . . . . 4.11
Replacement . . . . . . . . . . . . . . . . . . 4.12
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Service . . . . . . . . . . . . . . . . . . . . . . 4.13
Replacement . . . . . . . . . . . . . . . . . . 4.13
Crankshaft Position Sensor . . . . . . . . . . . . . . . . 4.13
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Replacement . . . . . . . . . . . . . . . . . . 4.13
Temperature / Barometric Air Pressure Sensor 4.14
Test (Refer to Diagnostic Software) . . . . . . . 4.14
Replacement . . . . . . . . . . . . . . . . . . 4.14
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . 4.14
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Replacement . . . . . . . . . . . . . . . . . . 4.15
TPS Initialization . . . . . . . . . . . . . . . . 4.15-4.16
Engine Temperature Sensor . . . . . . . . . . . . . . . 4.16
Test (Refer to Diagnostic Software) . . . . . . . 4.16
Replacement . . . . . . . . . . . . . . . . . . 4.16
Diagnostics using Blink Codes . . . . . . . . . . . . 4.17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Special Tools/Specifications/Torques . . . . . . . . . . . 9.2
Brake System Components . . . . . . . . . . . . . . . . . . . 9.3
Rear Caliper Exploded View . . . . . . . . . . . . . . . . . . 9.4
Front Caliper Exploded View . . . . . . . . . . . . . . . . . . 9.4
Rear Auxiliary Master Cylinder Exploded View . . 9.5
Brake System Service Notes . . . . . . . . . . . . . . . . . 9.5
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . 9.5
Hydraulic Brake System Overview . . . . . . . . . . . . . 9.6--9.7
Hydraulic Caliper Bleeding . . . . . . . . . . . . . . . . . . . 9.7
Brake Bleeding / Fluid Change . . . . . . . . . . . . . . . . 9.7--9.9
Master Cylinder Removal . . . . . . . . . . . . . . . . . . . . 9.9
Master Cylinder Installation . . . . . . . . . . . . . . . . . . . 9.9--9.10
Front Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10--9.11
Front Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9.12--9.13
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Front Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Front Disc Removal/Replacement . . . . . . . . . . . . . 9.13--9.14
Front Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . 9.14
Front Caliper Disassembly . . . . . . . . . . . . . . . . . . . 9.14-9.15
Front Caliper Inspection . . . . . . . . . . . . . . . . . . . . . . 9.15
Front Caliper Reassembly . . . . . . . . . . . . . . . . . . . . 9.15--9.16
Front Caliper Installation . . . . . . . . . . . . . . . . . . . . . 9.17
Rear Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17--9.18
Rear Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . 9.18
Rear Caliper Removal/Inspection . . . . . . . . . . . . . . 9.19--9.20
Rear Caliper Reassembly . . . . . . . . . . . . . . . . . . . . 9.20--9.21
Rear Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.21
Rear (Auxiliary) Brake Remove/Install . . . . . . . . . . 9.22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
Crankshaft Position Sensor Gap . . . . . . . . . . . . . . 10.2
Gear Position Switch Test . . . . . . . . . . . . . . . . . . . . 10.2
Instrument Cluster Overview . . . . . . . . . . . . . . . . . 10.3--10.7
Speedometer Removal/Installation . . . . . . . . . . . . 10.8
Speedometer Operation Troubleshooting . . . . . . 10.9--10.13
Coolant Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . 10.14
Fan Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
Fan Control Switch Tests . . . . . . . . . . . . . . . . . . . . 10.14
Electronic Throttle Circuit System Operation . . . . 10.15
Flywheel Identification . . . . . . . . . . . . . . . . . . . . . . . 10.16
Ignition System Operation . . . . . . . . . . . . . . . . . . . 10.16
Ignition Components . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Ignition System Troubleshooting . . . . . . . . . . . . . . 10.18--10.19
Charging System Testing . . . . . . . . . . . . . . . . . . . . 10.19
Fan / ECU Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Charging System Testing Flow Chart . . . . . . . . . . 10.21
Battery Identification . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Conventional Battery Activation/Service . . . . . . . . 10.22--10.23
Low Maint. Battery Activation/Service . . . . . . . . . . 10.24--10.28
Head Light/ Lamp / Switch Service . . . . . . . . . . . . 10.28--10.32
Work / Brake Light Lamp /Switch Service . . . . . . 10.32--10.34
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Accessory Wire Connections . . . . . . . . . . . . . . . . . 10.35
Winch Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 10.36
Starter System Troubleshooting . . . . . . . . . . . . . . . 10.37
Starter Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 1
ACTUAL INDEX WITH PAGE/SUBSECTION NUMBERS:
========================================
A
A-Arm Replacement, 5.16
Air Filter Service, 2.20
Alternator Output Test, 10.19
ATV Specifications, 1.3, 1.4, 1.5
Auxiliary Brake Removal, 9.22
B
Back Lash Pad Adjustment, 7.15
Battery Charging, 10.25, 10.26, 10.28
Battery Check Before Install, 10.25
Battery Installation, 10.23, 10.27
Battery Maintenance, 2.16, 10.25
Battery Service, 10.22, 10.23, 10.24, 10.25,
10.27, 10.28
Battery Storage, 2.36
Battery Terminal Bolts, 10.23
Battery Testing, 10.24, 10.27
Battery, Off Season Storage, 10.25, 10.28
Bleeding Procedure,4--Stroke Cooling System,
3.61
Body Assembly Exploded View, 5.11
Body Rack Exploded View, 5.12
Brake Bleeding/Fluid Change, 9.7, 9.8, 9.13, 9.17
Brake Caliper Disassembly, Front, 9.14
Brake Caliper Exploded View, Front, 9.4
Brake Caliper Exploded View, Rear, 9.4, 9.23
Brake Caliper Inspection, Front, 9.15
Brake Caliper Installation, Front, 9.16
Brake Caliper Removal, Front, 9.14
Brake Caliper Removal/Inspection, Rear, 9.19
Brake Disc Inspection, Front, 9.13
Brake Disc Inspection, Rear, 9.21
Brake Disc Removal/Replacement, Front, 9.13
Brake Fluid Level, 2.28
Brake Hose/Fitting Inspection, 2.29
Brake Light Switch Testing, 10.34
Brake Light, Work Light, Replacement, 10.33
Brake Master Cylinder Exploded View, Rear, 9.5,
9.22
Brake Noise, 9.5
Brake Pad Assembly, Front, 9.12
Brake Pad Inspection, 2.28
Brake Pad Installation, Rear, 9.18
Brake Pad Removal, Front, 9.10
Brake Pad Removal, Rear, 9.17
Brake System Inspection, 2.28
Brake System Main Components, 9.3
Brake System Operation, 9.6
Brake, Auxiliary, Hydraulic, 2.29
Brake, Auxiliary, Testing, 2.29
Breather Filter Maintenance, 2.21
Breather Hose Inspection, 2.22
Brush Replacement, Starter Motor, 10.39
C
Cam Gear Assembly, 3.41
Cam Gear Disassembly , 3.40
Cam Gear Removal, 3.40
Camber & Caster, 2.25
Camshaft Inspection, 3.47
Charging System Break Even Test, 10.19
Charging System Testing, 10.21
Cleaning the ATV, 2.35
Clutch Alignment, 6.18
Clutch Offset, 6.18
Cold Weather Heater Plug, 1.6
Combustion Chamber, 3.25
Compression Test, 2.15
Controls Inspection, 2.30
Coolant Level Inspection , 2.19
Coolant Strength, 2.18
Coolant Temperature Sensor, 10.14
Cooling System Hoses, 2.19
Cooling System Overview , 2.18
Cooling System Test, 2.19
Crank Position Sensor, 4.13
Current Draw, 10.18
CV Joint Handling Tips, 7.22
CV Shaft Boot, Inspection, 2.30
Cylinder Head Assembly, 3.27
Cylinder Head Disassembly, 3.22, 3.23
Cylinder Head Inspection, 3.22
Cylinder Head Reconditioning, 3.25
Cylinder Head Removal, 3.21, 3.28
Cylinder Head Warpage, 3.22
Cylinder Honing, 3.19
Cylinder Inspection, 3.32
Cylinder Removal/Inspection, 3.31
D
Decal Replacement, 5.20
Decimal Equivalents, 1.13
Diagnostic Codes, 4.18
Diagnostic Mode, 10.4
Diagnostic Mode, Service Interval, 10.5
Drive Belt Installation, 6.17
Drive Belt Removal/Inspection, 6.16
Drive Clutch Assembly, 6.15
Drive Clutch Disassembly, 6.11, 6.12, 6.13
Drive Clutch Exploded View, 6.2
Drive Clutch Inspection, 6.11
Drive Clutch Operation, 6.4
Drive Shaft Boot Inspection, 7.3
Drive Shaft Boot Replacement, 7.4
Driven Clutch Assembly, 6.24
Driven Clutch Operation, 6.4, 6.5
Dual Hydraulic Caliper Bleeding, 9.7
E
EBS Drive Clutch Bushing Service, 6.19
EBS Drive Clutch Inspection, 6.13
EBS Driven Clutch Disassembly, 6.21
EBS Driven Clutch Disassembly, Late 2004, 6.27
EBS Exploded View, 6.3
EBS Moveable Sheave Bushing Inspection, 6.14
EBS One Way Drive Clutch Inspection, 6.13
EFI Component Locations, 4.5
EFI Diagnostic Mode, 10.6
EFI System Exploded View, 4.4
EFI System Overview, 4.7
Electronic Control Unit, 4.8
Engine Accessible Components, 3.9
Engine Bottom End Disassembly, 3.31, 3.32, 3.34
Engine Bottom End Disassembly/Inspection, 3.47
Engine Break in Period, 3.18
Engine Designation Numbers, 1.2
Engine Exploded View, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7
Engine Fogging, 2.35
Engine Head Assembly, 3.29, 3.30
Engine Lower Disassembly/Inspection, 3.38
Engine Lower Reassembly, 3.47
Engine Lubricatin, 3.19
Engine Removal, 3.16
Engine Serial Number Location, 1.2
Engine Service Data, 3.12, 3.13, 3.14
Engine Temperature Sensor, 4.17
Engine to Frame Ground, 2.18
Engine Top End Disassembly, 3.21, 3.24, 3.28
ETC Operation Test, 10.15
ETC Switch Adjustment, 2.14
ETC Switch Testing, 10.15
Exhaust Canister Maintenance, 2.36
Exhaust System, Maintenance, 2.27
F
Fan Control Circuit Testing, 10.14
Fan Control Switch Bypass Test, 10.14
Fan Motor Current Draw Test, 10.14
Flywheel Identification, 10.16
Foot Well Removal / Install, 5.4
Frame, Nuts, Bolts, Fasteners, 2.32
Front / Rear Storage Compartment, 2.32
Front Axle Installation, 7.3
Front Axle Removal, 7.2
Front Cab Removal / Installation, 5.8
Front Cover Removal / Install, 5.4
Front Drive Axle Exploded View, 7.8
Front Gearcase Assembly/Inspection, 7.13
Front Gearcase Diagnosis -- Centralized Hilliard,
7.16
Front Gearcase Disassembly, 7.10
Front Gearcase Exploded View -- Centralized Hilliard,
7.18
Front Gearcase Operation, 7.9
Front Hub Assembly, 7.5
Front Hub Disassembly, 7.5
Front Prop Shaft Removal, 7.6
Front Storage Installation, 5.7
Front Storage Removal, 5.5
Front Strut Assembly, 5.18
Front Strut Ball Joint Replacement, 5.19
Front Strut Weldment Replacement, 5.19
Fuel Filter, 4.12
Fuel Filter Maintenance, 2.15
Fuel Injector, 4.12
Fuel Pressure Regulator, 4.11
Fuel Pump Service, 4.9, 4.18
Fuel Sender, Test, 10.34, 10.35
Fuel Stabilizer, 2.35
Fuel Tank Assembly, Exploded View, 4.6
G
Gear Circuit Readings, Instrument Cluster, 10.5
Gear Position Switch Test, 10.2
Gear Shift Selector Removal, 8.4
Gearcase Assembly, Rear , 7.28
Gearcase Coil Resistance, Front, 7.11
Gearcase Disassembly, Rear , 7.26
Gearcase Exploded View, Rear , 7.30
Gearcase Installation, Front, 7.17
Gearcase Installation, Rear , 7.29
Gearcase Lubricatin, Front, 2.11
Gearcase Lubricatin, Rear, 2.12
Gearcase Removal, Front, 7.9
Glossary of Terms, 1.14
H
Headlamp Service, 10.30, 10.31, 10.32
Headlamp Switch Testing, 10.32
Headlight Adjustment, 10.31, 10.32
High Engine Coolant Temperature, 10.3
High/Low Battery Voltage, 10.3
Honing to Oversize, 3.19
Hub Installation, Rear, 7.20
Hub Removal, Rear, 7.19
I
Ignition System Components, 10.17
Instrument Cluster Overview, 10.3
K
Keys, Replacement, 1.6
L
Load Test, 10.24, 10.28
Lubricatin Charts, 2.9, 2.10
Lubricatin, Transmission, 2.13, 8.4
M
Mag Cover Seal Replacement, 3.53
MAINTENANCE AND LUBRICATIN, 2.3, 2.4,
2.5
Maintenance, ATV Component Location, 2.6
Master Cylinder Installation, 9.9
Master Cylinder Removal, 9.9
Model & Serial Number Location, 1.
O
Odometer, Tachometer,Trip Meter, 10.3
Oil / Water Pump Disassembly, 3.44
Oil Check , Engine, 2.23
Oil Filter Change, 2.24
Oil Flow, 3.20
Oil Pressure Test, 3.19
Oil Rotor Clearance, 3.44
P
Paint Codes, 1.6
Periodic Maintenance Chart, 2.3, 2.4, 2.5
Piston Identification, 3.9
Piston Removal, 3.31
Piston Ring Installed Gap, 3.35, 3.37
Piston to Cylinder Clearance, 3.33
Piston/Rod Inspection, 3.34
Plastic Insert Removal, 5.2
Progammable Service Interval, Diagnostic Mode,
10.3
Publication Numbers, 1.6
Push Rod Inspection, 3.21
PVT Assembly, 6.8
PVT Disassembly, 6.7
PVT Drying, 2.22, 6.5
PVT Maintenance, 6.5
PVT Operation, 6.4
PVT Overheating, 6.6
PVT System Sealing/Ducting Components, 6.2
PVT Troubleshooting, 6.28
R
Radiator Coolant Level Inspection, 2.19
Radiator Front Cover Removal, 2.20, 5.10
Radiator, Maintenance, 2.19
Rear Cab Removal / Installation, 5.9
Rear Caliper Assembly, 9.20
Rear Drive Shaft Installation, 7.23
Rear Drive Shaft Removal, 7.22
Rear Drive Shaft Service, 7.24
Hub Assembly, Rear , 7.21
Hub Disassembly, Rear , 7.21
Rear Rack Removal / Installation, 5.7
Rear Storage Compartment Removal, 5.9
Rear Suspension Exploded View, 5.17
Rocker Arm Inspection, 3.21
S
Sediment Tube, Maintenance, 2.21
Shift Linkage Adjustment, 2.15
Shift Weights, 6.10
Side Panel Removal, 5.3
Solid State Relay, 10.20
Spark Plug Maintenance, 2.17
Special Tools, 1.7, 1.8, 2.8, 4.2, 5.2, 7.2, 9.2
Special Tools, Engine, 3.9
Special Tools, PVT, 6.4
Specifications, Brake, 9.2
Specifications, Cooling System, 3.15
Specifications, Drive Clutch Spring, 6.9
Specifications, Torque, Brakes, 9.2
Specifications, Torque, Engine, 3.10
Specifications, Torque, Final Drive, 7.2
Specifications, Torque, PVT, 6.4
Specifications, Torque, Standard, 1.11
Specifications, Torque, Steering, 5.2
Specifications, Torque, Suspension, 5.2
Specifications, Torque, Transmission, 8.4
Speedometer Installation, 10.8
Speedometer Troubleshooting, 10.9, 10.10,
10.11, 10.12, 10.13
Speedometer Removal, 10.8
Spider Disassembly, 6.22
Spider Removal, 6.12
Starter Assembly, 10.40, 10.42
Starter Disassembly, 10.37
Starter Drive, 10.41
Starter Drive Removal/Inspection, 3.36
Starter Motor Armature Testing, 10.39
Starter Motor Brush Inspection/Replacement,
10.38
Starter Motor Cleaning, 10.39
Starter Solenoid Bench Test, 10.41
Starter System Test, 10.43
Stator Removal/Inspection, 3.37, 3.38
Steering Maintenance, 2.25
Steering Post Assembly, 5.20
ATV Cleaning & Storage , 2.35
Storage Tips, 2.35, 2.36
Suspension Preload Adjustment, 2.29
Suspension, Front, Inspection, 2.30
Suspension, Rear, Inspection, 2.30
T
Tap Drill Chart, 1.13
Temperature & Barometric Sensor (T--Bap), 4.14
Throttle Cable Adjustment, 2.14
Throttle Operation, 2.14
Throttle Position Sensor, 4.15
Tie Rod Inspection, 2.25
Tire Inspection, 2.32
Tire Pressure, 2.31
Tire Tread Depth, 2.32
Toe Alignment, 2.26, 2.27
Torque Patterns, Engine, 3.11
Transmission Disassembly, 8.6
Transmission I.D. Location, 1.2
Transmission Information, 8.4
Transmission Installation, 8.5
Transmission Reassembly, 8.11
Transmission Removal, 8.4
Transmission, Exploded View, 8.2, 8.3
Transporting the ATV, 2.36, 3.8
Trigger Coil Gap, 10.2
Troubleshooting, Brakes, 9.23
Troubleshooting, Cooling System, 3.60
Troubleshooting, Engine, 3.59, 3.60
Troubleshooting, Fuel System, 4.19
Troubleshooting, Ignition System, 10.18
Troubleshooting, Spark Plug, 3.59
Troubleshooting, Starter System, 10.37
U
U--Joint Assembly, 7.7
U--Joint Disassembly, 7.6
Unit of Measure Conversion Table, 1.12
V
Valve Inspection, 3.24
Valve Lifter Removal/Inspection, 3.31
Valve Seal Testing, 3.28
Valve Seat Inspection, 3.25
Valve Seat Reconditioning, 3.25, 3.26, 3.27
Vent Line Maintenance, 2.15
VIN Identification, 1.2
Voltage Drop Test, 10.37
Voltage Test Open Circuit, 10.24, 10.27
W
Washing the ATV, 2.35
Water/Oil Pump Removal, 3.43
Waxing the ATV, 2.35
Wheel Inspection, 2.31
Wheel Installation, 2.31
Wheel Removal Front or Rear, 2.31
Wheel, Hub Torque, 2.31
Winch Operation, 2.33
Winch Wiring, 10.36
Worklight Switch, 10.32
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SERVICE MANUAL COVERS:
===================
( JUST A PART OF THE FULL TABLE OF CONTENTS / INDEX SHOWN HERE ...)
GENERAL
MAINTENANCE
ENGINE
ELECTRONIC FUEL INJECTION
CLUTCHING
FINAL DRIVE
BODY AND STEERING
TRANSMISSION
BRAKES
ELECTRICAL
Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
2005 Sportsman EFI Dimensions . . . . . . . . . . . 1.3
Specifications - Sportsman EFI . . . . . . . . . . . . 1.4--1.5
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.6
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.6
Standard Torque Specifications . . . . . . . . . . . . 1.6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7--1.10
Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.13
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.5
Component Locations . . . . . . . . . . . . . . . . . . . . 2.6
Lubricant and Maintenance Product Numbers 2.7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Lubricatin Charts . . . . . . . . . . . . . . . . . . . . . . . . 2.9-2.10
Front & Rear Gearcase Lubricatin . . . . . . . . . 2.11-2.12
Transmission Lubricatin . . . . . . . . . . . . . . . . . . 2.13
Throttle Cable Adjustment . . . . . . . . . . . . . . . . . 2.14
Transmission Linkage Inspection . . . . . . . . . . . 2.15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.15-2.16
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.16-2.17
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Coolant System Maintenance . . . . . . . . . . . . . . 2.18-2.20
Radiator Screen Removal . . . . . . . . . . . . . . . . . 2.20
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.20-2.21
Air Box Sediment Tube Service . . . . . . . . . . . . 2.21
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21-2.22
PVT Drying & PVT Drain Plug . . . . . . . . . . . . . . 2.22
Oil Change/Filter . . . . . . . . . . . . . . . . . . . . . . . . . 2.23-2.24
Steering and Toe Alignment . . . . . . . . . . . . . . . 2.25-2.27
Exhaust System Maintenance . . . . . . . . . . . . . 2.27-2.28
Brake System Service . . . . . . . . . . . . . . . . . . . . 2.28-2.29
Suspension Service . . . . . . . . . . . . . . . . . . . . . . 2.29-2.30
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Wheel/Tire --Removal/Installation/Inspection . 2.31-2.32
Warn® Winch Operation . . . . . . . . . . . . . . . . . . 2.33-2.34
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . 2.35-2.36
800 EFI Exhaust Canister Maintenance . . . . . 2.36
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . 3.2--3.7
Exhaust System View / Notes . . . . . . . . . . . . . . . . . 3.8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Engine Fastener Torque Patterns . . . . . . . . . . . . . 3.11
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . 3.12--3.14
Cooling System Specifications . . . . . . . . . . . . . . . . 3.15
Cooling System Test . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Engine Removal/Installation . . . . . . . . . . . . . . . . . . 3.16--3.17
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . 3.17--3.18
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Rocker Arm/Pushrod Inspection . . . . . . . . . . . . . . . 3.21
Cylinder Head Disassembly/Inspection . . . . . . . . . 3.21--3.23
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . 3.25
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . 3.25--3.27
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . 3.27
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Valve Train Exploded View. . . . . . . . . . . . . . . . . . . . 3.28
Engine Head Reassembly . . . . . . . . . . . . . . . . . . . . 3.29--3.30
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Valve Lifter Removal/Inspection . . . . . . . . . . . . . . . 3.31
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31--3.32
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32--3.33
Piston/Rod/Ring Service . . . . . . . . . . . . . . . . . . . . . 3.33--3.35
Starter Bendix Removal/Inspection . . . . . . . . . . . . 3.36
Flywheel/Stator Removal/Inspection . . . . . . . . . . . 3.37
Flywheel/Stator Installation . . . . . . . . . . . . . . . . . . . 3.37--3.38
Engine Crankcase Disassembly/Inspection . . . . . 3.38--3.46
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Engine Crankcase Assembly . . . . . . . . . . . . . . . . . 3.47--3.58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59--3.60
4--Stroke Coolant System Bleeding Procedure . . 3.61
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
EFI System Exploded View . . . . . . . . . . . . . . . . 4.4--4.5
Fuel Tank Exploded View . . . . . . . . . . . . . . . . . . 4.6
Electronic Fuel Injection System . . . . . . . . . . . 4.7
Operation Overview . . . . . . . . . . . . . 4.7
Initial Start/Priming Procedure . . . . . . 4.7
Electronic Control Unit . . . . . . . . . . . . . . . . . . . 4.8
Service . . . . . . . . . . . . . . . . . . . . . . 4.8
Replacement . . . . . . . . . . . . . . . . . . 4.8
Fuel Pump/Tank Assembly . . . . . . . . . . . . . . . . 4.9
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.9-4.10
Replacement . . . . . . . . . . . . . . . . . . 4.10--4.11
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . 4.11
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Replacement . . . . . . . . . . . . . . . . . . 4.11
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Service . . . . . . . . . . . . . . . . . . . . . . 4.11
Replacement . . . . . . . . . . . . . . . . . . 4.12
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Service . . . . . . . . . . . . . . . . . . . . . . 4.13
Replacement . . . . . . . . . . . . . . . . . . 4.13
Crankshaft Position Sensor . . . . . . . . . . . . . . . . 4.13
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Replacement . . . . . . . . . . . . . . . . . . 4.13
Temperature / Barometric Air Pressure Sensor 4.14
Test (Refer to Diagnostic Software) . . . . . . . 4.14
Replacement . . . . . . . . . . . . . . . . . . 4.14
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . 4.14
Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Replacement . . . . . . . . . . . . . . . . . . 4.15
TPS Initialization . . . . . . . . . . . . . . . . 4.15-4.16
Engine Temperature Sensor . . . . . . . . . . . . . . . 4.16
Test (Refer to Diagnostic Software) . . . . . . . 4.16
Replacement . . . . . . . . . . . . . . . . . . 4.16
Diagnostics using Blink Codes . . . . . . . . . . . . 4.17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Special Tools/Specifications/Torques . . . . . . . . . . . 9.2
Brake System Components . . . . . . . . . . . . . . . . . . . 9.3
Rear Caliper Exploded View . . . . . . . . . . . . . . . . . . 9.4
Front Caliper Exploded View . . . . . . . . . . . . . . . . . . 9.4
Rear Auxiliary Master Cylinder Exploded View . . 9.5
Brake System Service Notes . . . . . . . . . . . . . . . . . 9.5
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . 9.5
Hydraulic Brake System Overview . . . . . . . . . . . . . 9.6--9.7
Hydraulic Caliper Bleeding . . . . . . . . . . . . . . . . . . . 9.7
Brake Bleeding / Fluid Change . . . . . . . . . . . . . . . . 9.7--9.9
Master Cylinder Removal . . . . . . . . . . . . . . . . . . . . 9.9
Master Cylinder Installation . . . . . . . . . . . . . . . . . . . 9.9--9.10
Front Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10--9.11
Front Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9.12--9.13
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Front Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Front Disc Removal/Replacement . . . . . . . . . . . . . 9.13--9.14
Front Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . 9.14
Front Caliper Disassembly . . . . . . . . . . . . . . . . . . . 9.14-9.15
Front Caliper Inspection . . . . . . . . . . . . . . . . . . . . . . 9.15
Front Caliper Reassembly . . . . . . . . . . . . . . . . . . . . 9.15--9.16
Front Caliper Installation . . . . . . . . . . . . . . . . . . . . . 9.17
Rear Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17--9.18
Rear Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . 9.18
Rear Caliper Removal/Inspection . . . . . . . . . . . . . . 9.19--9.20
Rear Caliper Reassembly . . . . . . . . . . . . . . . . . . . . 9.20--9.21
Rear Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.21
Rear (Auxiliary) Brake Remove/Install . . . . . . . . . . 9.22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
Crankshaft Position Sensor Gap . . . . . . . . . . . . . . 10.2
Gear Position Switch Test . . . . . . . . . . . . . . . . . . . . 10.2
Instrument Cluster Overview . . . . . . . . . . . . . . . . . 10.3--10.7
Speedometer Removal/Installation . . . . . . . . . . . . 10.8
Speedometer Operation Troubleshooting . . . . . . 10.9--10.13
Coolant Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . 10.14
Fan Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
Fan Control Switch Tests . . . . . . . . . . . . . . . . . . . . 10.14
Electronic Throttle Circuit System Operation . . . . 10.15
Flywheel Identification . . . . . . . . . . . . . . . . . . . . . . . 10.16
Ignition System Operation . . . . . . . . . . . . . . . . . . . 10.16
Ignition Components . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Ignition System Troubleshooting . . . . . . . . . . . . . . 10.18--10.19
Charging System Testing . . . . . . . . . . . . . . . . . . . . 10.19
Fan / ECU Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Charging System Testing Flow Chart . . . . . . . . . . 10.21
Battery Identification . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Conventional Battery Activation/Service . . . . . . . . 10.22--10.23
Low Maint. Battery Activation/Service . . . . . . . . . . 10.24--10.28
Head Light/ Lamp / Switch Service . . . . . . . . . . . . 10.28--10.32
Work / Brake Light Lamp /Switch Service . . . . . . 10.32--10.34
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Accessory Wire Connections . . . . . . . . . . . . . . . . . 10.35
Winch Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 10.36
Starter System Troubleshooting . . . . . . . . . . . . . . . 10.37
Starter Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 1
ACTUAL INDEX WITH PAGE/SUBSECTION NUMBERS:
========================================
A
A-Arm Replacement, 5.16
Air Filter Service, 2.20
Alternator Output Test, 10.19
ATV Specifications, 1.3, 1.4, 1.5
Auxiliary Brake Removal, 9.22
B
Back Lash Pad Adjustment, 7.15
Battery Charging, 10.25, 10.26, 10.28
Battery Check Before Install, 10.25
Battery Installation, 10.23, 10.27
Battery Maintenance, 2.16, 10.25
Battery Service, 10.22, 10.23, 10.24, 10.25,
10.27, 10.28
Battery Storage, 2.36
Battery Terminal Bolts, 10.23
Battery Testing, 10.24, 10.27
Battery, Off Season Storage, 10.25, 10.28
Bleeding Procedure,4--Stroke Cooling System,
3.61
Body Assembly Exploded View, 5.11
Body Rack Exploded View, 5.12
Brake Bleeding/Fluid Change, 9.7, 9.8, 9.13, 9.17
Brake Caliper Disassembly, Front, 9.14
Brake Caliper Exploded View, Front, 9.4
Brake Caliper Exploded View, Rear, 9.4, 9.23
Brake Caliper Inspection, Front, 9.15
Brake Caliper Installation, Front, 9.16
Brake Caliper Removal, Front, 9.14
Brake Caliper Removal/Inspection, Rear, 9.19
Brake Disc Inspection, Front, 9.13
Brake Disc Inspection, Rear, 9.21
Brake Disc Removal/Replacement, Front, 9.13
Brake Fluid Level, 2.28
Brake Hose/Fitting Inspection, 2.29
Brake Light Switch Testing, 10.34
Brake Light, Work Light, Replacement, 10.33
Brake Master Cylinder Exploded View, Rear, 9.5,
9.22
Brake Noise, 9.5
Brake Pad Assembly, Front, 9.12
Brake Pad Inspection, 2.28
Brake Pad Installation, Rear, 9.18
Brake Pad Removal, Front, 9.10
Brake Pad Removal, Rear, 9.17
Brake System Inspection, 2.28
Brake System Main Components, 9.3
Brake System Operation, 9.6
Brake, Auxiliary, Hydraulic, 2.29
Brake, Auxiliary, Testing, 2.29
Breather Filter Maintenance, 2.21
Breather Hose Inspection, 2.22
Brush Replacement, Starter Motor, 10.39
C
Cam Gear Assembly, 3.41
Cam Gear Disassembly , 3.40
Cam Gear Removal, 3.40
Camber & Caster, 2.25
Camshaft Inspection, 3.47
Charging System Break Even Test, 10.19
Charging System Testing, 10.21
Cleaning the ATV, 2.35
Clutch Alignment, 6.18
Clutch Offset, 6.18
Cold Weather Heater Plug, 1.6
Combustion Chamber, 3.25
Compression Test, 2.15
Controls Inspection, 2.30
Coolant Level Inspection , 2.19
Coolant Strength, 2.18
Coolant Temperature Sensor, 10.14
Cooling System Hoses, 2.19
Cooling System Overview , 2.18
Cooling System Test, 2.19
Crank Position Sensor, 4.13
Current Draw, 10.18
CV Joint Handling Tips, 7.22
CV Shaft Boot, Inspection, 2.30
Cylinder Head Assembly, 3.27
Cylinder Head Disassembly, 3.22, 3.23
Cylinder Head Inspection, 3.22
Cylinder Head Reconditioning, 3.25
Cylinder Head Removal, 3.21, 3.28
Cylinder Head Warpage, 3.22
Cylinder Honing, 3.19
Cylinder Inspection, 3.32
Cylinder Removal/Inspection, 3.31
D
Decal Replacement, 5.20
Decimal Equivalents, 1.13
Diagnostic Codes, 4.18
Diagnostic Mode, 10.4
Diagnostic Mode, Service Interval, 10.5
Drive Belt Installation, 6.17
Drive Belt Removal/Inspection, 6.16
Drive Clutch Assembly, 6.15
Drive Clutch Disassembly, 6.11, 6.12, 6.13
Drive Clutch Exploded View, 6.2
Drive Clutch Inspection, 6.11
Drive Clutch Operation, 6.4
Drive Shaft Boot Inspection, 7.3
Drive Shaft Boot Replacement, 7.4
Driven Clutch Assembly, 6.24
Driven Clutch Operation, 6.4, 6.5
Dual Hydraulic Caliper Bleeding, 9.7
E
EBS Drive Clutch Bushing Service, 6.19
EBS Drive Clutch Inspection, 6.13
EBS Driven Clutch Disassembly, 6.21
EBS Driven Clutch Disassembly, Late 2004, 6.27
EBS Exploded View, 6.3
EBS Moveable Sheave Bushing Inspection, 6.14
EBS One Way Drive Clutch Inspection, 6.13
EFI Component Locations, 4.5
EFI Diagnostic Mode, 10.6
EFI System Exploded View, 4.4
EFI System Overview, 4.7
Electronic Control Unit, 4.8
Engine Accessible Components, 3.9
Engine Bottom End Disassembly, 3.31, 3.32, 3.34
Engine Bottom End Disassembly/Inspection, 3.47
Engine Break in Period, 3.18
Engine Designation Numbers, 1.2
Engine Exploded View, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7
Engine Fogging, 2.35
Engine Head Assembly, 3.29, 3.30
Engine Lower Disassembly/Inspection, 3.38
Engine Lower Reassembly, 3.47
Engine Lubricatin, 3.19
Engine Removal, 3.16
Engine Serial Number Location, 1.2
Engine Service Data, 3.12, 3.13, 3.14
Engine Temperature Sensor, 4.17
Engine to Frame Ground, 2.18
Engine Top End Disassembly, 3.21, 3.24, 3.28
ETC Operation Test, 10.15
ETC Switch Adjustment, 2.14
ETC Switch Testing, 10.15
Exhaust Canister Maintenance, 2.36
Exhaust System, Maintenance, 2.27
F
Fan Control Circuit Testing, 10.14
Fan Control Switch Bypass Test, 10.14
Fan Motor Current Draw Test, 10.14
Flywheel Identification, 10.16
Foot Well Removal / Install, 5.4
Frame, Nuts, Bolts, Fasteners, 2.32
Front / Rear Storage Compartment, 2.32
Front Axle Installation, 7.3
Front Axle Removal, 7.2
Front Cab Removal / Installation, 5.8
Front Cover Removal / Install, 5.4
Front Drive Axle Exploded View, 7.8
Front Gearcase Assembly/Inspection, 7.13
Front Gearcase Diagnosis -- Centralized Hilliard,
7.16
Front Gearcase Disassembly, 7.10
Front Gearcase Exploded View -- Centralized Hilliard,
7.18
Front Gearcase Operation, 7.9
Front Hub Assembly, 7.5
Front Hub Disassembly, 7.5
Front Prop Shaft Removal, 7.6
Front Storage Installation, 5.7
Front Storage Removal, 5.5
Front Strut Assembly, 5.18
Front Strut Ball Joint Replacement, 5.19
Front Strut Weldment Replacement, 5.19
Fuel Filter, 4.12
Fuel Filter Maintenance, 2.15
Fuel Injector, 4.12
Fuel Pressure Regulator, 4.11
Fuel Pump Service, 4.9, 4.18
Fuel Sender, Test, 10.34, 10.35
Fuel Stabilizer, 2.35
Fuel Tank Assembly, Exploded View, 4.6
G
Gear Circuit Readings, Instrument Cluster, 10.5
Gear Position Switch Test, 10.2
Gear Shift Selector Removal, 8.4
Gearcase Assembly, Rear , 7.28
Gearcase Coil Resistance, Front, 7.11
Gearcase Disassembly, Rear , 7.26
Gearcase Exploded View, Rear , 7.30
Gearcase Installation, Front, 7.17
Gearcase Installation, Rear , 7.29
Gearcase Lubricatin, Front, 2.11
Gearcase Lubricatin, Rear, 2.12
Gearcase Removal, Front, 7.9
Glossary of Terms, 1.14
H
Headlamp Service, 10.30, 10.31, 10.32
Headlamp Switch Testing, 10.32
Headlight Adjustment, 10.31, 10.32
High Engine Coolant Temperature, 10.3
High/Low Battery Voltage, 10.3
Honing to Oversize, 3.19
Hub Installation, Rear, 7.20
Hub Removal, Rear, 7.19
I
Ignition System Components, 10.17
Instrument Cluster Overview, 10.3
K
Keys, Replacement, 1.6
L
Load Test, 10.24, 10.28
Lubricatin Charts, 2.9, 2.10
Lubricatin, Transmission, 2.13, 8.4
M
Mag Cover Seal Replacement, 3.53
MAINTENANCE AND LUBRICATIN, 2.3, 2.4,
2.5
Maintenance, ATV Component Location, 2.6
Master Cylinder Installation, 9.9
Master Cylinder Removal, 9.9
Model & Serial Number Location, 1.
O
Odometer, Tachometer,Trip Meter, 10.3
Oil / Water Pump Disassembly, 3.44
Oil Check , Engine, 2.23
Oil Filter Change, 2.24
Oil Flow, 3.20
Oil Pressure Test, 3.19
Oil Rotor Clearance, 3.44
P
Paint Codes, 1.6
Periodic Maintenance Chart, 2.3, 2.4, 2.5
Piston Identification, 3.9
Piston Removal, 3.31
Piston Ring Installed Gap, 3.35, 3.37
Piston to Cylinder Clearance, 3.33
Piston/Rod Inspection, 3.34
Plastic Insert Removal, 5.2
Progammable Service Interval, Diagnostic Mode,
10.3
Publication Numbers, 1.6
Push Rod Inspection, 3.21
PVT Assembly, 6.8
PVT Disassembly, 6.7
PVT Drying, 2.22, 6.5
PVT Maintenance, 6.5
PVT Operation, 6.4
PVT Overheating, 6.6
PVT System Sealing/Ducting Components, 6.2
PVT Troubleshooting, 6.28
R
Radiator Coolant Level Inspection, 2.19
Radiator Front Cover Removal, 2.20, 5.10
Radiator, Maintenance, 2.19
Rear Cab Removal / Installation, 5.9
Rear Caliper Assembly, 9.20
Rear Drive Shaft Installation, 7.23
Rear Drive Shaft Removal, 7.22
Rear Drive Shaft Service, 7.24
Hub Assembly, Rear , 7.21
Hub Disassembly, Rear , 7.21
Rear Rack Removal / Installation, 5.7
Rear Storage Compartment Removal, 5.9
Rear Suspension Exploded View, 5.17
Rocker Arm Inspection, 3.21
S
Sediment Tube, Maintenance, 2.21
Shift Linkage Adjustment, 2.15
Shift Weights, 6.10
Side Panel Removal, 5.3
Solid State Relay, 10.20
Spark Plug Maintenance, 2.17
Special Tools, 1.7, 1.8, 2.8, 4.2, 5.2, 7.2, 9.2
Special Tools, Engine, 3.9
Special Tools, PVT, 6.4
Specifications, Brake, 9.2
Specifications, Cooling System, 3.15
Specifications, Drive Clutch Spring, 6.9
Specifications, Torque, Brakes, 9.2
Specifications, Torque, Engine, 3.10
Specifications, Torque, Final Drive, 7.2
Specifications, Torque, PVT, 6.4
Specifications, Torque, Standard, 1.11
Specifications, Torque, Steering, 5.2
Specifications, Torque, Suspension, 5.2
Specifications, Torque, Transmission, 8.4
Speedometer Installation, 10.8
Speedometer Troubleshooting, 10.9, 10.10,
10.11, 10.12, 10.13
Speedometer Removal, 10.8
Spider Disassembly, 6.22
Spider Removal, 6.12
Starter Assembly, 10.40, 10.42
Starter Disassembly, 10.37
Starter Drive, 10.41
Starter Drive Removal/Inspection, 3.36
Starter Motor Armature Testing, 10.39
Starter Motor Brush Inspection/Replacement,
10.38
Starter Motor Cleaning, 10.39
Starter Solenoid Bench Test, 10.41
Starter System Test, 10.43
Stator Removal/Inspection, 3.37, 3.38
Steering Maintenance, 2.25
Steering Post Assembly, 5.20
ATV Cleaning & Storage , 2.35
Storage Tips, 2.35, 2.36
Suspension Preload Adjustment, 2.29
Suspension, Front, Inspection, 2.30
Suspension, Rear, Inspection, 2.30
T
Tap Drill Chart, 1.13
Temperature & Barometric Sensor (T--Bap), 4.14
Throttle Cable Adjustment, 2.14
Throttle Operation, 2.14
Throttle Position Sensor, 4.15
Tie Rod Inspection, 2.25
Tire Inspection, 2.32
Tire Pressure, 2.31
Tire Tread Depth, 2.32
Toe Alignment, 2.26, 2.27
Torque Patterns, Engine, 3.11
Transmission Disassembly, 8.6
Transmission I.D. Location, 1.2
Transmission Information, 8.4
Transmission Installation, 8.5
Transmission Reassembly, 8.11
Transmission Removal, 8.4
Transmission, Exploded View, 8.2, 8.3
Transporting the ATV, 2.36, 3.8
Trigger Coil Gap, 10.2
Troubleshooting, Brakes, 9.23
Troubleshooting, Cooling System, 3.60
Troubleshooting, Engine, 3.59, 3.60
Troubleshooting, Fuel System, 4.19
Troubleshooting, Ignition System, 10.18
Troubleshooting, Spark Plug, 3.59
Troubleshooting, Starter System, 10.37
U
U--Joint Assembly, 7.7
U--Joint Disassembly, 7.6
Unit of Measure Conversion Table, 1.12
V
Valve Inspection, 3.24
Valve Lifter Removal/Inspection, 3.31
Valve Seal Testing, 3.28
Valve Seat Inspection, 3.25
Valve Seat Reconditioning, 3.25, 3.26, 3.27
Vent Line Maintenance, 2.15
VIN Identification, 1.2
Voltage Drop Test, 10.37
Voltage Test Open Circuit, 10.24, 10.27
W
Washing the ATV, 2.35
Water/Oil Pump Removal, 3.43
Waxing the ATV, 2.35
Wheel Inspection, 2.31
Wheel Installation, 2.31
Wheel Removal Front or Rear, 2.31
Wheel, Hub Torque, 2.31
Winch Operation, 2.33
Winch Wiring, 10.36
Worklight Switch, 10.32
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