2004–2005 Polaris Sportsman 500 6x6 ATV Service Manual (P/N 9919504)

This Polaris service manual, P/N 9919504, covers the 2004–2005 Sportsman 500 6x6, models A04CL50AA and A05CL50AA, with maintenance, diagnostic and repair procedures.

• Engine repair: Engine removal, cylinder-head and valvetrain service, piston and ring installation, crankshaft inspection, oil-pump service and crankcase assembly.

• Fuel and cooling: Mikuni BST 34 carburetor disassembly and adjustment, fuel-pump service, cooling-system pressure tests, bleeding and water-pump mechanical seal replacement.

• PVT and transmission: Drive and driven clutch inspection, bushing replacement, belt alignment and deflection checks, gear-selector service and internal transmission repair.

• 6x6 final drive: AWD Hilliard clutch and Demand Drive Hub service, front gearcase overhaul, middle and rear axle repairs, and drive-chain adjustment.

• Chassis and brakes: Concentric swingarm, MacPherson strut, A-arm and ball-joint procedures, plus master-cylinder service, caliper repair and dual hydraulic brake bleeding.

• Electrical diagnosis: DC/CDI ignition, charging and starter tests, ECM logic-box operation, Electronic Throttle Control checks, and separate instrument-cluster information for each model year.

Suited to experienced ATV technicians with precision measuring equipment; Polaris specifies certified Master Service Dealer technicians and factory-authorized tools for PVT maintenance and repair.

Engine Service and Water-Pump Seal Repair

The EH50PL engine chapters cover valve-seat reconditioning, cylinder and piston inspection, crankshaft and counterbalancer end-play checks, and oil-pump inspection and assembly. Fastener torque patterns and the staged cylinder-head tightening procedure accompany the assembly instructions. The EH50PL Oil Flow Diagram traces the feed and scavenging circuits.

Water-pump mechanical seal replacement is documented with the engine installed, using puller P/N 2872105. Side-loading the puller can bend the pump shaft; replacing that shaft requires engine removal and crankcase separation.

Carburetor Testing and Maintenance References

The BST 34 carburetor exploded view is paired with float-height adjustment, needle-and-seat leakage testing and fuel-level checks. Fuel-pump diaphragm tests and temperature/altitude jetting charts support fuel-delivery diagnosis.

Periodic maintenance and lubrication charts cover the transmission, gearcases and chassis. Reference material also includes optional spring, paint-code and replacement-key charts.

Clutch, Transmission and Axle Service

PVT troubleshooting relates belt slip, overheating and erratic engagement to clutch wear, alignment, deflection and duct sealing. Transmission procedures extend to shift forks, engagement dogs, chains and bearings; installation identifies the Center Distance Tool, P/N 2871710.

The final-drive chapter covers magnetic hub coils, armature plates, CV boots, front gearcase components, and the concentric swingarm’s middle axle and bearing housing. Overstretching the Hilliard clutch garter spring reduces its tension and can cause unintended front-hub engagement at speed; the manual specifies installation tool P/N 2870888.

Electrical Tests and Build-Specific Wiring

The Ignition System Testing Flow Chart and Charging System Testing Flow Chart accompany component checks, starter voltage-drop tests, ECM pin descriptions, thermistor tests and ETC fault checks.

Separate instrument-cluster sections distinguish the two model years. Wiring sheets cover the 2004 model and 2005 builds before and after July 12, 2004, helping match connector and wire references to the correct configuration before tracing a fault.

Instrument-cluster diagnosis and replacement are covered, while the internal memory battery and illumination lamp are described as non-serviceable.

Suspension, Body and Hydraulic Brakes

Gen VI chassis procedures include strut-cartridge replacement, swingarm pivot service and steering adjustment. The Dump Box Exploded View identifies the tailgate, latches, hinges and support shock.

The brake chapter explains the separate hydraulic circuits in the dual-system rear caliper, with bleeding instructions, seal inspection, pad adjustment and disc wear checks.

When working on drivetrain components, hydraulic brakes or fuel systems, securely support the chassis and observe the manual’s safety precautions.

Valve Clearance and Lubrication Data: A Preview

These are a few of the valve-adjustment and lubrication specifications included in the manual.

Intake and exhaust valve clearance is .006 in. (.15 mm), checked cold at TDC on the compression stroke. Engine oil capacity is 2.0 U.S. quarts (1.9 L).

Hot-engine oil pressure is specified at 20 PSI standard and 12 PSI minimum at 5500 RPM with Polaris Premium 4 Synthetic 0W-40 oil. The transmission lubrication specification lists 32 ± 1.6 oz. of AGL Gearcase Lubricant.

Printable PDF, Search and Wiring Detail

Text search and diagrams: Service-chapter text is searchable, with embedded chapter and topic bookmarks. Wiring-sheet labels are not text-searchable; rotate and zoom the sheets to read small wire codes and connector numbers.

Supplied as one printable English-language PDF with 286 pages, including the opening chapter overview, five Notes pages, six index pages and the original rear cover. These pages are already included in the total.