Polaris Sportsman 2005 Service
Polaris Sportsman · 2005 · service manual · 312 pages
Technical data
Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.
Tightening torque
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| Drain plug | 15 N·m | p. 30 | |
| Sealing washer toque | 14.9 N·m | 15 N·m | p. 31 |
| Radiator hose clamp | 4.1 N·m | 36 in·lb | p. 40 |
| Front Wheel Nuts | 36.6 N·m | 37 N·m | p. 53 |
| Front Spindle Nut | 94.9 N·m | 95 N·m | p. 53 |
| Front Hub Nut | 94.9 N·m | 95 N·m | p. 54 |
| Drive Clutch Bolt 7/16 | 55 N·m | p. 62 | |
| Cylinder Base | 35.3 ± 2.85 N·m | 26 ft·lb | p. 65 |
| Ring Profile | 8.1 N·m | 8 N·m | p. 104 |
| Bolts evenly | 27.1 N·m | 27 N·m | p. 111 |
| Bracket | 2.7 N·m | 24 in·lb | p. 118 |
| Fuel Valve | 3 N·m | p. 118 | |
| T--27 screws | 4.1 N·m | 4 N·m | p. 140 |
| Bushing | 41 N·m | p. 148 | |
| A-Arm Tube | 10.8 N·m | 8 ft·lb | p. 148 |
| Washer | 11 N·m | p. 148 | |
| A-Arm Tube | 33.9 N·m | 25 ft·lb | p. 148 |
| Cotter pin holes | 40.7 N·m | 41 N·m | p. 148 |
| Spacer | 24.4 N·m | 18 ft·lb | p. 150 |
| Pinch bolts | 20.3 N·m | 21 N·m | p. 151 |
| Strut Rod Nut | 20.3 N·m | 21 N·m | p. 151 |
| Drive Clutch Retaining Bolt | 54.2 N·m | 54 N·m | p. 154 |
| Driven Clutch Retaining Bolt | 23 N·m | 23 N·m | p. 154 |
| PVT Inner Cover Bolts | 16.3 N·m | 16 N·m | p. 154 |
| Drive Clutch Spider EBS Clutch | 271.2 N·m | 200 ft·lb | p. 154 |
| Upward on drive clutch sheaves | 271 N·m | p. 154 | |
| Drive Clutch Spider Lock Nut | 20.3 N·m | 15 ft·lb | p. 154 |
| Drive Clutch Cover Plate | 10.2 N·m | 10 N·m | p. 154 |
| Short, sharp jerks, remove drive shaft from | 94.9 N·m | 95 N·m | p. 191 |
| O-ring and bolts | 19 N·m | 19 N·m | p. 201 |
| Cover Bolts | 19 N·m | 19 N·m | p. 203 |
| Mounting bolts | 40.7 N·m | 41 N·m | p. 205 |
| Insert bearing carrier on drive shaft | 36.6 N·m | 37 N·m | p. 208 |
| Suspension components | 108.5 N·m | 109 N·m | p. 211 |
| Transmission | 24.4 N·m | 25 N·m | p. 220 |
| Auxiliary Brake | 27.1 N·m | 27 N·m | p. 221 |
| Cover Bolts | 46.1 N·m | 34 ft·lb | p. 233 |
| Anvil Bolts | 24.4 N·m | 18 ft·lb | p. 240 |
| Washers | 25 N·m | p. 240 | |
| O--rings | 3.4 N·m | 30 in·lb | p. 240 |
| Brake Pads | 6.8 N·m | 60 in·lb | p. 240 |
| Bleeder Screw | 6.5 N·m | p. 240 | |
| Bleeder Screw | 3.4 N·m | p. 244 | |
| Bolt first | 0.6 N·m | 5 in·lb | p. 245 |
| Line and banjo bolt | 20.3 N·m | 15 ft·lb | p. 246 |
| Line and banjo bolt | 21 N·m | p. 246 | |
| Hand Master Cylinder Clamp Bolt | 2.8 N·m | 3 N·m | p. 246 |
| Brake Line Banjo Bolt | 20.3 N·m | 21 N·m | p. 246 |
| Front Caliper Mounting Bolts | 24.4 N·m | 24 N·m | p. 248 |
| Front Wheel Nut runout exceeds | 36.6 N·m | 37 N·m | p. 249 |
| Brake Disc Thickness Variance | 24.4 N·m | 24 N·m | p. 249 |
| Rear Brake | 24.4 N·m | 24 N·m | p. 257 |
| Brake Disc Thickness | 48 N·m | p. 257 | |
| Transmission park lock mechanism | 20.3 N·m | 15 ft·lb | p. 258 |
| Brake Reservoir | 20.3 N·m | 15 ft·lb | p. 258 |
| Brake Reservoir | 21 N·m | p. 258 | |
| MC Bolts | 10.8 N·m | 8 ft·lb | p. 258 |
| Bushing | 11 N·m | p. 258 |
Spark plugs
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| EH50PL | — | p. 61 | |
| EH42PLE | — | p. 62 |
Service intervals
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| Coolant change | 2 years | p. 23 |
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