Name: Polaris 2005 Sportsman MV7 Service manual
Brand: Polaris
Rating: 5 (1 reviews)

4. Table of Contents
6. Model Identification
7. Publications Numbers / Replacement Keys
8. 2005 Sportsman MV
9. Jetting chart
10. Special Tools
15. Standard Torque Specifications
16. Conversion Table
18. Glossary of Terms
20. Periodic Maintenance Chart
21. Maintenance and lubrication
22. GENERAL
25. Polaris lubricant symbol identification
28. Pre-Ride Inspection
29. Front Gearcase Lubrication
30. Transmission Lubrication/Linkage Inspect...
31. Rear Gearcase Lubrication
32. Lubrication / Grease Points
33. Idle speed adjustment
35. MAINTENANCE
36. Vent lines
37. Battery Maintenance
38. Spark plug
39. Liquid cooling system
40. Radiator coolant level
42. Breather Filter / Line Inspection
43. Recoil Housing
44. PVT Drying & PVT Drain Plug
45. Oil and filter change
48. Toe alignment
51. Auxiliary brake testing
52. Controls
54. Warn ® Winch Operation
56. Cleaning and Storage
58. Maintenance schedule
60. Engine Exploded Views
63. Top end
65. Special Tools
66. Torque Specifications
67. Engine Fastener Torque Patterns
68. 600 ENGINE SERVICE DATA
72. Cooling System Specifications
74. PVT SYSTEM
76. Oil Flow
77. Rocker Arm/Pushrod Inspection
78. Cylinder head warpage
80. Valve Inspection
81. Combustion Chamber
83. Cylinder Head Assembly
84. Valve Sealing Test
85. Engine Head Reassembly
87. Cylinder Removal
88. Cylinder Inspection
91. Piston ring installed gap
92. Starter Bendix Removal/Inspection
93. Flywheel/Stator Removal/Inspection
95. Engine Crankcase Disassembly/Inspection
103. Camshaft Inspection
104. Engine Crankcase Assembly
116. Troubleshooting
122. Fuel Flow Diagram
123. Carburetor Jetting
124. CV Carburetor System Function (4 Cycle)
126. Float system
128. Carburetor inspection
129. Carburetor assembly
130. Needle & Seat Leakage Test
131. Fuel Level
132. Fuel Sender Service
136. Plastic Insert Removal/Install
137. Side Panel Removal
138. Front Cover Removal/Install
140. Front Rack/Brushguard Removal/Install
143. Rear Rack/Brushguard Removal/Install
144. Warn ® Winch Removal/Installation
147. Headlight Pod Exploded View
148. Handlebar Block Installation Procedure
149. BODY ASSEMBLY EXPLODED VIEW
153. A-Arm Replacement
154. Rear Suspension Assembly
155. Strut assembly
156. Front Strut Cartridge Replacement
157. Steering Post Assembly
160. Drive Clutch Exploded View
161. PVT Operation Overview
162. Pvt drying
163. PVT Overheating/Diagnosis
164. PVT Cover Removal/Install
165. PVT Disassembly
166. PVT Assembly/Inspection
167. Drive clutch spring specifications
168. Shift Weights /Inspection
169. Shift weight inspection
171. Drive Clutch Reassembly
172. Drive Belt Removal/Inspection
174. Drive Belt Installation
175. Clutch offset
176. Moveable sheave bushing inspection
177. Driven Clutch Disassembly/Assembly
184. Removal and installation
185. Troubleshooting
187. FINAL DRIVE
191. Front hub assembly
194. Awd front drive axle exploded view
206. Rear hub installation
207. Rear Hub Disassembly/Assembly
208. Rear Drive Shaft Removal
209. Rear Driveshaft Installation
210. Rear Driveshaft Service
212. Rear Gearcase Service
215. Rear gearcase installation
218. TRANSMISSION EXPLODED VIEW
220. TRANSMISSION
221. Transmission Installation
222. Transmission Disassembly
227. Transmission Reassembly
235. Brake System Components
236. Rear Caliper Exploded View
237. Brake System Service Notes
238. Hydraulic Brake System Overview
239. Hydraulic Caliper Bleeding
241. Master Cylinder Removal
242. Front Pad Removal
244. Front Pad Assembly
245. Brake Burnishing
246. Front Caliper Removal
247. Front Caliper Inspection
248. Front Caliper Installation
249. Rear Pad Removal
250. Rear Pad Installation
251. Rear Caliper Removal/Inspection
252. Rear caliper assembly
253. Rear Disc Inspection
255. Troubleshooting
257. ELECTRICAL
258. Trigger Coil Gap Procedure
259. ECM Operation / Overview
260. Instrument Cluster Overview
262. Diagnostic mode
264. Speedometer Removal/Installation
266. Speedometer Operation Troubleshooting
272. Fan motor current draw
273. Etc operation test
274. Flywheel Identification
276. Ignition System Testing Flow Chart
277. Ignition System Troubleshooting
279. Alternator output test
280. Charging system testing flow chart
281. Battery Identification
283. Load test
284. Charging procedure
285. Battery charging
286. Battery testing
287. Low maintenance battery charging
288. High beam headlight bulb replacement
292. Fuel sender test
295. Starter motor removal
297. Armature testing
299. Starter drive
301. Starter system testing flow chart

Description

The Service Manual for the Polaris 2005 Sportsman MV7 and Offroad Vehicle provides detailed instructions for service and maintenance of the vehicle. It includes information on model identification, publications numbers, jetting specifications, and torque settings. It also includes illustrations of the electrical wiring diagrams, fuel system diagrams, and suspension diagrams. The Service Manual provides step-by-step instructions for routine maintenance, including oil and filter changes, spark plug replacement, and brake system adjustments. It also covers troubleshooting and repair of the vehicle when things go wrong. The manual provides detailed instructions on how to diagnose and repair common problems, as well as tips on how to make sure the vehicle is running at its best. The Service Manual is a must-have for anyone who owns a Polaris 2005 Sportsman MV7 and Offroad Vehicle. It provides the information needed to keep the vehicle running smoothly and safely. With the Service Manual, you can be sure that you are getting the most out of the vehicle.

File size: 124.36 MB

Created: January 30, 2023

Last updated: March 20, 2023