Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
1.4
MODEL:
2004 SPORTSMAN 500 6x6
. . . . . . . . . .
MODEL NUMBER: A04CL50AA .
ENGINE MODEL: EH500PLE104 . .
Engine
Platform Fuji 4 stroke, Single Cylinder
Engine Model Number EH500PLE104
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 1200
±
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 142.5
Pilot Air Jet 160
Jet Needle--clip position 4HB41--3
Needle Jet Q--4M (829)
Pilot Screw 3 Turns Out
Float Height 13
±
1 mm (0.51
±
0.40“)
Fuel Delivery/Tank Capacity Fuel Pump
Fuel Capacity / Requirement 4.25 gal. (16.09L)
87 Octane (minimum)
89 Oxygenated
Electrical
Alternator Output 250 w @ 5000 RPM
Voltage Regulator 3--Phase
Lights : High Beam 50 watts
Low Beam 27 watts
Brake 26.9 watts
Tail 8.26 watts
Ignition System DC/CDI Ignition
Ignition Timing 30
° ±
2
°
BTDC @ 5000 RPM
Spark plug / Gap NGK BKR5E/ .036 in . / 0.9 mm
Battery / Model / Amp Hr Sealed Low Maintenance --
14 Amp Hr
Circuit Breakers Solid State in ECM
Starting Electric / Recoil Backup
Instrument Cluster LCD
Drivetrain
Transmission Type H--Pattern H/L/N/R
Transmission Fluid Capacity 32 oz.
Front Gearcase Capacity 4 oz. (120 ml)
Front Hub Capacity 2.5 oz. (75 ml)
Gear Ratio : Low
High
Rev.
Final
6.69/1
3.34/1
5.17/1
12/38 80 P chain
Clutch Type PVT
Belt 3211077
Steering / Suspension
Front Suspension / Shock A--arm / MacPherson Strut
Front Travel 6.7 in. / 17.02 cm
Rear Suspension
Style / Shock
Progressive Rate Single
Rear Travel Center 6.5 in. / 16.5 cm
Rear 7.5 in / 19.1 cm
Ground Clearance 5.5 in. / 14 cm
Shock Preload Adjustment
Front / Rear
F --Spring tension -- Std.
R -- Cam Adjustment
Turning Radius 119 in. / 302 cm unloaded
Toe Out 0 -- 1/16 in / .0 -- .159 mm
Wheels / Brakes
Wheel Size -- Front 25 x 8 -- 12 / 4--156
Wheel Size -- Center / Rear 25 x 11 -- 10 / 4--156
Air Press. F/R Tires 5 psi Front / 5 psi Rear
Brake -- Front Dual Hydraulic Disc
Brake -- Rear 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
147.5 142.5
140 135
CLUTCH CHART
Altitude
Meters
(Feet)
0--1800
(0--6000)
1800--3700
(6000--12000)
Shift
Drive
Spring Driven
Helix
Weight
10 MH
10 WH
40
°
Spring
Red
(5630513)
(5630710)
(7041198)
(5131446)
Blu/Grn
(7041157)
(7041157)
40
°
(5131446)
Blu/Grn
Red
(7041198)
2--2
2--2
Above 40
°
F
Above 5
°
C
Driven