Essential Maintenance: Polaris Sportsman 500 6x6 (2004-2005)

Polaris Sportsman 500 6x6 ATV Service Manual (2004-2005) - Professional Maintenance & Repair Guide

Maximize the performance and longevity of your workhorse with this definitive digital service manual. Specifically designed for the 2004 and 2005 Polaris Sportsman 500 6x6, this guide offers far more than basic instructions—it provides the deep technical insight required to maintain the unique six-wheel drive system and the legendary Fuji-built 500 powerplant.

Whether you are performing a routine oil change or a complete engine overhaul, this manual delivers the precision data used by factory-certified technicians.

Detailed Model Coverage:

• Sportsman 500 6x6 (2004) - Model No. A04CL50AA
• Sportsman 500 6x6 (2005) - Model No. A05CL50AA

Core Technical Specifications & Engine Insights:

At the heart of these machines is the high-performance Fuji 4-stroke, Single Cylinder engine. This manual covers every nuance of the EH500PLE engine series (EH500PLE104 for 2004 and EH500PLE106 for 2005).

• Engine Power: 499cc displacement with a 92 x 75 mm bore and stroke.
• Cooling System: Liquid-cooled with a 2.25-quart capacity, featuring a pressurized dry sump lubrication system.
• Carburetion: Precise settings for the Mikuni BST 34mm carburetor, including pilot screw adjustments (standard 2 turns out) and jetting charts for various altitudes.
• Drivetrain: Detailed service for the H-Pattern transmission (H/L/N/R) and the heavy-duty 12/38 80 P final drive chain.

Essential Identification & Serial Numbers:

Finding the right parts starts with correct identification. This manual explains exactly where to find your vehicle's critical numbers:

• Machine Serial Number: Stamped on the lower left side of the frame tube.
• Engine Serial Number: Located on a sticker on the recoil housing (right side) and stamped on the center top of the crankcase.
• Transmission I.D.: Found on top of the transmission on the right side of the machine.
• VIN Breakdown: Complete guide to deciphering your 17-digit Vehicle Identification Number.

High-Value Content for Owners:

• Advanced Troubleshooting: From DC/CDI ignition failures to PVT (Polaris Variable Transmission) belt slippage, solve issues before they become costly repairs.
• Comprehensive Maintenance Charts: Specialized schedules for "Severe Use" (mud, water, or heavy load operation), essential for the 6x6's typical utility environment.
• Electrical Mastery: Full wiring diagrams for 2004 and 2005 models, including logic box (ECM) operation and instrument cluster diagnostic modes.
• Precision Torque Specs: Every bolt matters. Get the exact foot-pounds for cylinder head bolts (11mm), flywheel nuts (58-72 ft. lbs.), and wheel nuts (50 ft. lbs. for rear/middle).
• Fluid & Lubricant Guide: Use the right products, such as Polaris Premium 4 Synthetic 0W-40 and AGL Gearcase Lubricant, with exact capacities provided for every component.

Table of Contents Highlights:

• General Information: Dimensions, special tools, and conversion charts.
• Engine & Carburetion: Valve clearance (.006" for intake/exhaust), piston identification, and fuel pump testing.
• PVT System: Clutch offset, alignment, and drive belt maintenance (Belt PN 3211077).
• Final Drive: Middle and rear axle drive chain adjustments and eccentric locking procedures.
• Brakes & Suspension: Hydraulic disc service, master cylinder bleeding, and strut preload adjustments.

This manual is the ultimate resource for keeping your Polaris Sportsman 500 6x6 in peak condition, ensuring it remains the most capable tool in your arsenal. Optimize your repair workflow with professional-grade data today.