2005 Polaris Sportsman MV7
Contents
1.2. WI RMINATION TABL COLOR GAUG PROM CONNECTOR T6 CONNECTOR 0 BLAC 20 CD SPLICE 2 02 BROW 6 GROUND SPLICE 2 03 BLAC 20 SPEEDOMETER SPLICE die 04 BLUE WHITE 20 SPEEDOMETER SSCB 1 05 YELLOW UPPER HEADLIGHT LH HANDLEBAR 06 BROW 6 POWER POINT SPLICE 1 01 BROW 6 FAN MOTOR SPLICE 2 08 BROW 20 SPEEDOMETER SPLICE t 09 BROW 4 GROUND FRAME GROUND 0 BROWN YELLOW UPPER HEADLIGHT DULL HE d RED WHITE 20 SPEEDOMETER SPLICE 1 2 BROW 20 FTC AND AWD SWITCH SPLICE 1 3 GREE LH HANDLEBAR SIUE 4 GREEN WHITE TRANS SWITCH RESISTOR MODULE 5 YELLOW RED 20 CD SPEEDOMETER 6 GRAY ORANGE 20 SPEEDOMETER LH HANDLEBAR 1 ORANGE TAILLIGHT BRAKE LIGHT SENSOR 8 PURPLE TRANS SWITCH RESISTOR MODULE 9 BROW 20 LH HANDLEBAR SPLIOM 20 RED 6 HUS BEE NK SGD 2 RED 6 FUSIB NK S S Claes 22 BROWN SSCB 1 GROUND Ge RED WHITE IGNITION SWITCH SP dii 24 RED WHITE 6 LH HANDLEBAR 5 ICE 1 BLACK WHITE WINCH SELECI FRONT CONTACTOR 26 ORANGE BLACK 6 SSCB FAN MOTOR 21 GREEN WHITE WINCH SELECI FRONT 28 BROW 20 PUL SENDER SPLICE GREE LH HEADLIGHT SP LAAC Ea 30 GRE 20 SPEEDOME SPEEDO DARNOS ebe
3. MILITARY USE ONLY 1081302 HONIM 2 121145 AND HOLIMS JI LS0N9V10 00334 2465 2 LEI UNI 10310075 HONIM A 121145 YOLOVINOD 4 38 458 4 4215 5 L opis O Bree ET 4 ee E SCT Det 994 el TWNOIS 9 O 0 7 5 0 2 829 4015 1401158 Nas dand BOSS IS 8255 JINGOW 40151534 IS 8255 8 1 JINGOW 40151544 JINGOW 0151543 Ad E 42145 ee Ado OE YOLOVINOD 4NIOd 43MOd po 4140145 20148 E ODAH JINGOW YOLSIS4Y 31148 O 1 20145 HOLIMS SNYXL DITSONSVIG 043345 AVGTIQNVH HI HOLIMS NOTIINS JILSONOVIO 043345 RE RS SE E YOIIVINOD INOUj YOLOW YOLIVINOD LNOYS HOLIMS 97 81 IDN Te D NO SSES 2 8l Won 08 PC Y 8i NMOSQ MOll3J 6 Wl 8I NMONG MOTI34 8L Wiad Wi LE 8l 1489 zeg SR 85 NMOUG 91 JOSN3S IH911 Qt JLIHN 039 GL y 101035 HNIN WALL vig L4 ais HONIM WS 541059 HOLIMS Yl M M IL 7 Ww Ugo uvis 81 W eS Begleed 595 HOI IMS OWN NN 2 13 0121145 BCT gt
4. Y BRN Les CONTACTOR Engt AP EC 1 pe Hh reg dr xl E DEEST l NORMAL OPERATION 15 OPEN CIRCUIT IF CLOSED ASSEMBLY COVER ADJUSTMENT 1 REQUIRED ETC SWITCH B ag ct POWER E 0 BRN POINT E 49 oni 1 m P NEN 215 ep 64 ORN W AWD LOCATED BELOW HEAD LAMPS 64 ORN W J 53 e e LEFT HANDLEBAR SWITCH ASSEMBLY B rk START Ez Lt 3 pUe S gJ LOW 52 R BLK Ar OE 19 BRN NEU 16 GRY ORN E e 9REV 4 52 R BLK 1340 24 TRANSMISSION EE TAIL LAMP eee rear er R 6 GAUGE a EN TT FUSIBLE LINK KIT L P N 2202147 ES AA LK 6 GAUGE TT eu om STARTER MOTOR LOCATED IN FRONT OF FUEL TANK 11 OR 21 34 R N 15 R W SPEEDO BRAKE LAMP SWITCH Se _ WITH HAND BRAKE APPLIED BLK 6 GAUGE 09 BRN ZI 33 BLU 30 GRN 11 GRN 58 BRN GROUND O gt TO CDI GEAR STARTER SOLENOID SEE SHEET 2 SIGNAL LOCATED ON FRONT OF BATTERY 1 n n zd d MILITARY USE ONLY
5. MILITARY USE ONLY ll t ke Q WIRING DIAGRAM 2005 SPORTSMAN MV MILITARY VERSION 2005 SPORTSMAN MV MILITARY M IN FRONT Uum ATV 05 SPORTSMAN MV MILITARY MODEL NO AOSNH6SMA FUEL um INDE CONTROL PAGE 1 OF 2 SENDER WHEEL SPEED SENSOR REGULATOR e WIRES ARE REPRESENTED BY PURA E A wm gi SOLID OR DASHED LINES TO EMPTY 5 OHMS SIMPLIFY TRACING IN DIAGRAM FULL 90 ou 1 CIRCUIT See LAMP AND a SHOULD BE ON WITH BREAKERS THERMISTOR LEADS UNPLUGGED OR SHORTED 15 Rosy TO EACH OTHER L 9 H CODE N ENGINE GROUND BLACK LOCATED ON RIGHT FRONT BRAKE TO WINCH CONTROLS R BRN BROWN tu 2 0 gt 2 2 ee GRN GREEN CHASSIS GROUND e SEE SHEET 2 PUR PURPLE LLL Lu PI EDO RELAY PO 76 Q adn Y YELLOW LAMP 87 37 Y BLK 192 p W CONTROL R RED ae W WHITE w 30 TWO COLOR WIRES ARE SHOWN WITH E a MAIN TRACE COLORS EXAMPLE R Y RED WITH YELLOW TRACER 28 BRN 57 PUR W 48 BRN Y 36 GRN 42 BRN WINCH SELECT EE E EH DE N Jo SN N HARNESS 2410559 01 A29 GRN CSO 26569 Seene Ow TO STATOR IR SWITCH vu ay 77 i SEE SHEET 2 che oy Kit 25 BLK W FRONT
6. 3121195 99 CNN 19 NN 150 1 HOLIMS NOILIN9I KI a EIER o eL 00 yvig 89 8 03900 WI WO HOLIMS 213 WO 11 4 lNIOd H3M0d ol 91 1 311HW 39NVHO 0924 PONT wWOlA NMOUH o 9ILSONOVIO 003345 0 8 46807 81114001145 06 15 HOLIMS NOILINS9I SI JONVYO 90 ANNOYS 8l NMOUG 66 HOLIMS SNVUL 8 q34 30NYUO i 22V 9 27 3aiHwa3ews3so HOLIMS NOILINOI __ co IBBLIMS SNWUL 4 5 SNWUL 8 e Oc WOH 67 4 9 0v3H HI 8i MOTIJA NMOYgS 87 4 1445 8I day yovid 0313003345 02 3ilHWM 3ONYUO S i HOLIMS 213 07 E 0 7 OO f H9 10v3H HH 91 MOTISA NMON8 Ir 1L 4313N00113d 0c 31lHWNMONB Iv INSIS HO Oe Or pe E HG esl Lf OSS 8I OMOVIG MOlIJA 8 445 8I LE L __ 0 S Si oE 44300443450 Oc O3U NMOUH SE 805835 1 9011 3NVUg 9p HA gds te ET e ER HOLIMS NOT LING 01 z QION3IOS 1315 8i lC L CUNOdiddS A Oeo 23402 p 17 4 0 1dv3u n1 8I
7. FF Nes 7g To Splice 1 16 S pl ce 2 82 R W k SPEEDO DIAGNOSTIC NOTE When the IR lightis switched on all other lights IR LIGHT SWITCH TEST headlights brake instrument illumination Switched off Use ia Voltmeter to check for continuity in the IR OPERATION When the IR switch is turned to the SIT ON position the IR relay functions as follows First unplug the harness from the IR light and probe the wires that lead to Positive battery power is applied to the IR lamp via the Yellow Brown wire from the IR switch Positive battery power is applied to the IR relay via the second Yellow Brown wire thereby not continuity check the switch prongs for continuity Replace This opens the ground connection between the switch if no continuity is found Brown Yellow and Brown This disables the headlights taillight and brake lights Wer Place Leads Check for Continuity The Green wire is contacted to Brown Ground disabling the instrument display illumination 18 vm IR LIGHT TEST 7 on Harness Wires By IR Light the switch Turn the switch on and if there 15 continuity the switch is ok If there is Remove the connector to the IR light Probe the IR plug wires Brown and Yellow Brown at back of connector Turn IR light on IR Switch IR Switch Yellow Brown IR Light Plug Wires D POLARIS 10 2 MILITARY USE ONLY
8. MILITARY USE ONLY POLARIS The Way Out MILITARY SERVICE MANUAL ADDENDUM PN 9920082 Use this addendum with the 2005 Sportsman MV Service Manual PN 9919963 MILITARY USE ONLY MILITARY USE ONLY LARIS The Way Out use THE E NG EXPE Burr THE RIDING EXEL Work TO MAKE 2005 SPOR Military ore TSMAN MV al Addendum ord by certified Polaris Master Service Dealer technicians for reference All references to left and right side ve when seated in a normal riding position des procedures for maintenance operations component Identification and unit ifications for 2005 Polaris Sportsman MV7 ATVs Comments or suggestions be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina 2005 Sportsman MV Service Manual Military Addendum Copyright 2004 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in
9. THERMISTOR j 4 in 10 cm GROUND TRANS SWITCH WIRE END VIEW 32 in 81 cm ETC AND AWD SWITCH LR SWITCH 11 in SPEEDOMETER WIRE ENTRY VIEW a 28cm 7 WINCH CONTROL IGNITION SWITCH 5 in 13 cm POWER POINT 4in 10cm 2 in 5 cm Gy LM reo CONTACTOR 46 BLK Th GRN 14 in 35 cm 17 OR 15 R 9 BRN Y 73 in 185cm n a wo 4 in 10 cm TAILLIGHT LH HANDLEBAR JD POLARIS MILITARY USE ONLY ELECTRICAL MILITARY USE ONLY WIRING HARNESS 2005 SPORTSMAN MV MILITARY VERSION Main Wire Hamess Routing Harness PN 2410559 Rev O1 Serviceable Parts 2202147 Fusible Link
10. Nadao 6 YANas Jand 00 87 193135 HONTM Bi J 12 BOSS 94 OMOVIg 3ONYEO 92 7 413 Bi d3llHMD VIB Se CI 133HS 335 STOULNOD HONIM je e c SYOLOVINOD d 123135 E 108 1NO2 Es LNOYS HON TM HON IM c sue L uy ig 1 wu8 6 Nos deseo qo 18 NYG N 43MOd 16 Y4MOd N49 18 418 43MOd ON A 9318 OS 0 7 18 NU8 OS HEEN N NU JONVISTSSY TIYWS y YOLIANNOD 149 POLARIS MILITARY USE ONLY ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN MV MILITARY VERSION LT TWH e ads UG 3 2 eme er qo o 8 NN SOARS SOAS ES 00000000 WIOL 361 A0 We XS 859 O o WNIT Sid foe HESIN smia 3076 gaa 023 Ge 30911951 86 M ML TINGOW 4015 1538 HMIMSSNVHUI 8 3id d STC n mds e SWHO 61 0 H TERET ee E E EC HN a gen T HI IT 3imodiids Tu nl 191 BS Wa avos 18 1105 sage WnWdids 1d 04 MOTI 0310201 MOIS Bseo waere gea JINGOW 401S1 38 HMI
11. 1 IN THE 2005 SPORTSMAN MV7 MANUAL PROVIDED TO PROPERLY SERVICE THIS UNIT MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service Machine Model Number Identification 05 68 Emissions 6 Year Designation Basic Chassis Model Option Designation Engine Designation ENGINE DESIGNATION NUMBERS EHOOSOLETLI xn Twin cylinder Liquid Cooled 4 Stroke Electric Start VIN IDENTIFICATION Vehicle Identifier This could be either Individual Serial a number or a letter Emissions Model Engine Year Powertrain Check Digit Plant No Body Style ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine be sure to refer to the engine model number and serial number T his information can be found the sticker applied to the top side of the crank case A An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model numberand serial number are im portant for vehicle identification The machine serial number is stamped onthe lower left side of the frame tube B TRANSMISSION 1 0 NUMBER LOCATION The transmission 1 0 number is located the right side of machine 1 2 MILITARY US
12. 25 gal US T6 ltr Rear 4 0 gal US 15 87 Octane minimum 89 Oxygenated ENS NEIN 1 Pilot Screw Float Height Fuel Delivery Fuel Capacity Requirement Starting Electric Recoil Backup 1 4 Drumshift H L NJR ev P ark 152302 450m 10 2 7 300ml 5 07 150ml Transmission Type Transmission Capacity Rear Gearcase Capacity Front Gearcase Capacity Gear Ratio Low ah Rev High Front Drive Rear Drive Clutch Type Steering Suspension Front Sus pension Shock w EBS 3211091 MacPherson Strut 8 2 in 21 cm Progressive Rate Independent Two x 2 Coil over Shock 9 5 in 24 13 cm 10 5 in 26 7 cm Front Non Adjustable Rear Ratchet Style Std 71 5 in 181 6 cm unloaded 0 1 16 in 0 159 mm FrontTravel Rear Suspension Shock Rear Travel Ground Clearance S hock P reload Adjustment Front Rear Turning Radius Toe Out Wheels Brakes Wheel Size Pattern Front Wheel Size Pattern Rear 25x10 12 4 156 Recommended Air Pressure 5 psi Front F R 5 psi Rear Brake Front J ETTING CHART 25x8 12 4 156 Dual Hydraulic Disc Dual Hydraulic Disc AMBIENT TEMPERATURE Below 40 F Below 5 C Altitude Above 40 F Above 5 0 1800 0 6000 162 5 above 1800 above 6000 155 CLUTCH CHART EBS Models have no helix spring adjustment Drive Driven Driven Altitude Spring Spring
13. 3l WHITE RED START D IGNI AFON 52 RED BLAC IGN TT WON SW TER LH HANBLEBAR SS BLU 20 SPE E DOME LER S UND NOSTIC 34 RED WHIT DRAKE SENSOR EIN 2 29 BROWN RE 20 SWF DOME TER TRANS SWITCH 36 GRE HEADLIGHT SPLICE 1 SS YELLOW BLACK SSCB 2 ERMISTOR 38 YELLOW BLACK SSCB 2 ERMISTOR 39 BROW CD SPLICE 2 10 WHIT e U GEAR SIGNAT RESISTOR MODULE d DROWN WHITE 26 SP E E D Opa HUB COIL 4 ROWN YELLOW RH HEADL LGH T SPLICE 2 43 RED WHITE CD SPLICE 2 44 GRAY 20 AND WWD SWITCH HU 45 ORANGB WHIT 20 SPERDGME TER POWER POINT 46 BLAC KAR ED WINCH SPEC REAR CONTACTOR 41 RED PWR SSCB Ti ig ME 48 BROWN Y E FADLIGHT SPLICE 2 49 BROW 20 LH HANDLEBAR SPLICE 1 50 LUE RED TRANS SWITC RESISTOR MODULE 1 WHYTE BLUE TRANS SWITC REST STOR MODULE N RED BLACK IGNITION SWITCH LH HANDLEBAR KM ORANGE WHI 6 ACC 2 SSCB 91 ORANGE RED TRANS SWITCH RESISTOR MODULE 99 BROW GROUND 55 26 ORANGE IGNITION SWITCH SSCB 21 PURPCIQANH TE 20 SPEEDOMETER FUEL SENDER 28 BROW 20 SPEEDO DIAGNOSTIC SPLICE 59 BROWNYY EL LOW TAILLIGHT SPLICE 2 60 ORANGE WHITE 6 POWER POINT ACC 1 01 RED WHITE 20 AND AWD SWITCH SPLICE 62 ORANGE IGNITION SWITCH SSCB t 6 WHITE 20 SPEEDOMETER GEAR SIGNAL 64 ORANGE WHITE 6 ACC 1 ACC 2 P BROW 6 GROUND SPLICE 1 66 RED WHITE 6 SPLICE 1 SPLICE 2 61 BROW SPLICE 1 Sg Ko 68 BLAC 20 AND AWD SWITCH SPLICE 2 69 BROWN YELLOW 6 I R RELAY SPLICE 2
14. Key information to clarify instructions Trademarks Polaris acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Technologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trademark of Gold Eagle FOX Registered Trademark of Fox Shox Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of J ohn Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Ammco Registered Trademark of Ammco Tools Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation MILITARY USE ONLY MILITARY USE ONLY WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a THREE MONTH LIMITED WARRANT Y on all components of the Polaris MV 700 4x4 and the Polaris MV 500 6x6 ATVs against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transfer able to another consumer during the warranty period through a Polaris dealer REGISTRATION time of sale the Warranty Registration Form mustbe completed by yourdealer and submitted to P olaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verifica tion of registration will be sentto the pur
15. OFF RUN OFF p Recoil Start If the starter switch will not start the MV pull the recoil handle located on the right side of the machine The En gine RumSwiteh must be on POLARIS 1 6 MILITARY USE ONLY MILITARY USE ONLY SPORTSMAN MV CONTROLS Starter Switch Located on headlight pod Turn Switch to right to start MV Use choke if necessary AWD Control Throttle Lever Right Handlebar The throttle controls engine speed and vehicle move ment The AWD control switches the MV into AWD on demand See the Owner s Manual for more de tails on Polaris AWD Engine Stop Run Switch A Provides operator with ability to easily stop engine The switch must be in the run position to start the MV Mode Reverse Override Switch B This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also al lows activation of Demand 4 Drive All Wheel Drive in reverse if the Demand 4 Drive switch is on This switch is also used to toggle through the information center on the instrument cluster Headlamp Switch C Controls the headlights for High Beam Low Beam and Light shutoff Winch Control D The winch control give the oper ator the ability to control winch cable direction or In and Out ij POLARIS GENERAL INFORMATION Front Rear Winch Selectio
16. part is expressly prohibited Printed in U S A MILITARY USE ONLY MILITARY USE ONLY IMPORTANT NOTICE ABOUT THIS ADDENDUM This 2005 Sportsman MV Military Addendum should be used with the 2005 Sportsman MV Service Manual PN 9919963 to cover all serviceable components of the the Sportsman MV The material supplied in the 2005 Sportsman MV Military Addendum adds to the information supplied in the 2005 Sportsman MV Service Manual PN 9919963 This addendum is formatted in the same format as the service manual The following Chapter s have been supplied with this addendum to 2005 S ports man MV e Chapter 1 General Information amp Specs e Chapter 5 Body and Steering e Chapter 10 Wiring amp Wiring Schematic UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions important information is brought to your attention by the following symbols Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A DANGER Failure to follow DANGER instructions will result iq Severe injury ordeath to the operator bystander or person inspecting or servicing the ATV Failure to follow WARNING instructions could result in severe injury or death to the operator bystander or person inspecting or servicing the ATV CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or ATV or property damage NOTE A NOTE provides
17. 10 BROWN START SOLENOID SPLICE 2 GREEN RED WINCH SELEC REAR CONTACTOR be RED WHITE SWITCH SPLICE Ts GREE WINCH SELEC WINCH CONTRO 4 BLAC WINCH SELEC WINCH CONTRO 15 RED WHITE BRAKE LIGHT SENSOR TAILLIGHT 16 BROW LAMP SPLICE 2 1 GREE RELAY SPEEDO DIAGNOSTIC 18 YELLOW BROWN LAMP H SWITCH 80 YELLOW BROWN LAMP RELAY 80 BROW LAMP I R RELAY d BROW 6 I R RELAY SPLICE 2 82 RED WHITE SWITCH WINCH CONTROL MILITARY USE ONLY D POLARIS
18. E ONLY MILITARY USE ONLY GENERAL INFORMATION MODEL 2005 SPORTSMAN MV MODEL NUMBER AOSMH68MB ENGINE MODEL EHO680LE Category Length Width Height w Rollbar Wheel Base Dry Weight Gross Vehicle Weight Front Rack Capacity Rear Rack Capacity Towing Capacity Hitch Tongue Capacity Winch Capacity Front R ear Body Style 2005 SPORTSMAN MV7 Civilian Version Shown 1 3 D POLARIS MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION MODEL 2005 SPORTSMAN MV MODEL NUMBER A05MH68MB ENGINE MODEL EHO68OLE Platform Polaris Twin Cylinder EHO680LE017 683cc Engine Model Number Engine Displacement Number of Cylinders 80 x 68 mm 9 78 1 150 170 psi 1200 50 RPM 6000 Rpm 200 Rpm Liquid 3 2 qt 3 ltr HOT on Instrument Cluster Bore amp Stroke mm Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating Rpm Cooling System Capacity Overheat Warning Lubrication Pressurized Wet Sump Polaris OW 40 2 qt 1 9 ltr Single Pipe Oil Requirements Capacity Exhaust System Carburetion Carburetor model Mikuni BST 34mm Main J et 157 5 Pilot J et Pilot Air J et et Needle Clip Position Needle J et m 60 4HB41 4 6 829 Initial Setting 23 8 Turns Out Initial starting point setting may vary 13 mms 17 0 51 in 0 04 Fuel Pump Front 4
19. Helix 20 56 Blu Gm Wht Yel jm 5631215 7041157 7041635 5132751 1800 3700 20 54 Blu Gm Why Yel EBS 6000 12000 5631214 7041157 7041635 51 D POLARIS MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION PUBLICATION NUMBERS Model No Owner s Service Manual PN Manual PN Manual PN Manual Ad dendum Sportsman MV A05MH68MB 9919959 9919956 9919963 9920082 Military Version Contact Polaris Industries for copies of the Service Manual Addendum Other publications can be ordered through regular ordering routes PAINT CODES PAINTED COLOR POLARIS PART DESCRIPTION NUMBER Frame Flat Black P 463 Cab Order direct from Midwest Industrial Coatings 952 942 1840 eMixeas directed REPLACEMENT KEYS NOTE The military Sportsman MV s do not have a key start This is for informational purposes only Replacement keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost ignition switch re placement is required Series Part Number 22 Key Series Number 4010278 4010278 D POLARIS 15 MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION STARTING THE SPORTSMAN MV 1 Turn Engine Switch to RUN 2 Turn the Start Switch to the Right
20. MS 8i 31IHM N339 Fl 1 UO L L Bs 81 83388 V 1321195 HOLINS GRY 2 07 Zl 1 3018 auiwodis 04 Goal ONNOWO OL 1 BE 301796 93221 ei MOTTA o NY 62 0 WA 1109 9 Non 0 391195 139130003345 0 No 0 Leg 624 119 Nolo NJ O 9 X08 105 800 0 A OL A i 3s 3 Ns 90 02 4 89 0 16 S3ONVISTS 30 HT OE 60 we Des auimodis 02 6 n 391195 Himodids J 04 wid 0 31195 o Moe EE ee ee _ 0 HOLOSNNOD OL HOLJSNNOD 3onvo H0109 AR HOLY 193 JO 2 NOLLVNIWHSI JHM y 23004 ALYYLITINTAWTNYNSLYOdS 60 ALY XUV LIA AN NVINSLUOdS 9000 MILITARY USE ONLY ll t ke Q WIRING HARNESS 2005 SPORTSMAN MV MILITARY VERSION Main Wire Hamess Routing Harness PN 2410559 Rev O1 Serviceable Parts 2202147 Fusible Link NOTE The wiring hamess diagram is not scaled to the actual hamess size Measurements are g
21. ON BODY RACK EXPLODED VIE Front Rack Platform Corner Support Bracket Rubber Bumper Side Vent Headlight Front Brushguard Access Door Front Rack Support Front Brush Guard Mount Warn Winch K Tow Bar Assembly Pm VOD gt M 5 5 MILITARY USE ONLY MILITARY USE ONLY BODY STEERING SUSPENSION BODY RACK EXPLODED VIEW REAR RACK GAURD A Rear Rack B Rear Brush Guard C Rear Platform Mount D inch E Gorner Bracket F Channel Support G Clip Pin RACKS FOOT WELL ASSY A G B Front Rack C Roll Bar D Outside Rear Tube Footwell Plates F Gun G Tube Support H Inside Rear Tube 5 6 POLARIS MILITARY USE ONLY MILITARY USE ONLY ELECTRICAL CHAPTER EL ECT FRICA L 10 2 THIS IS UPDATED INFORMATION USE THIS INFORMATION WITH CHAPTER 5 2005 SPORTSMAN MV7 MANUAL PROVIDED TO PROPERLY SERVICE THIS UNIT gt POLARIS 10 1 MILITARY USE ONLY MILITARY USE ONLY ELECTRICAL IR RELAY OPERATION RELAY COIL 76 86 67 9 30 IK SWITCH ZN os Ol Eech
22. asy access to switeh between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulleddN or released OUT via the con trols on the handlebar 1 8 When the winch is FREESPOOL the winchyallows the cable to be pulled out freely NOTE The switch handlebar does have to be the OUT position SPARE PVT BELT Theres a spare PVT drive belt located under the left rear fender Forinstallation of the PVT belt refer to Chapter 6 inthe Service Manual provided D POLARIS MILITARY USE ONLY MILITARY USE ONLY BODY STEERING SUSPENSION CHAPTER 5 BODY AND STEERING 5 2 5 3 Accessory Guerney Install 00 5 4 Sri Zei REES EE 5 4 Rack Body Exploded View 5 5 5 6 NOTICE THIS IS UPDATED INFORMATION USE THIS INFORMATION WITH CHAPTER 5 IN THE 2005 SPORTSMAN MV7 MANUAL PROVIDED TO PROPERLY SERVICE THIS UNIT ij POLARIS 5 1 MILITARY USE ONLY MILITARY USE ONLY BODY STEERING SUSPENSION CHAPTER 5 BODY amp TOW BAR SETUP STEERING 1 Remove the tow bar secure pin from center of tow bar Remove the two tow bar secure pi NOTE The information for Chapter 5 has been each side of the bumper Extend the modified for the 2005 Sportsman MV7 military model section outward AN 2 Use this information in place of or with Chapte
23. chaser as the copy of the Warranty Registration F orm willbe the war ranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BEALLOWED UNLESS YOUR VE HICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very importantimensuring trouble free operation ur chasing a machine the crate or without proper dealer setup will void yourfwarranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does notcoverany vehicle thathas been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result oL dnauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint rfinish stress cracks tearing or puncturing of uphol stery material corrosion or defeets in parts components or the vehicle caused by fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not
24. compatible with the vehicle The exclusive remedy forbreach of this warranty shall be atP olaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY P OLARIS SHALL LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGESQOF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do notpermitthe exclusion or limitation of incidental or consequentialdamages orimplied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do notallow limitations on how long an implied war ranty lasts so the above limitation may not apply to you if inconsistent with controlling state law MILITARY USE ONLY MILITARY USE ONLY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Regist
25. iven as reference points to aid in locating wires and connectors To locate the reference point on the diagram use the measurements provided NOTE Measurements with an indicate that the measurement was taken from where the wires come off of the main hamess 4A in 10 cm 4in 10 GEAR ACC 2 ACC SIGNAL SPLICE 1 34 in cm 28 in 71 cm 11 in 28 cm CDI RH 42 BRN Y i HEADLIGHT 36 GR R R i 3 ORN 4 ORN 26 ORN BLK 7 BR 4 4 ORN 60 ORN uss 6 8 J K JD JC BA L A AS 1 1 16 BR 80 BR _ SPEEDO DIAGNOSTIC ees 4 in 10 cm HEADLIGHT i e T HUB Ini COIL SENDER SS i i 0 b P d T P 6 in T T 15 cm 28 BR 57 PUR 4 in 10 cm FAN SPLICE 2 LAMP MOTOR 15 cm WIRE END VIEW 11 in GE 12 50 in 8 in 20 cm 317756 m FRAME m GROUND in cm 41 RI SOLENOID 2 26 ORI BK START BATTERY 3 ORN SOLENOID t SSCB 4 IR RELAY 6 in 15 cili y H WIRE END VIEW H 1 2 CONTACTOR ALTERNATOR ead j1 s wr BRAKE LIGHT Lol t SENSOR T 6 in 15 cm 16 in 41 cm 28 in 71 cm LH 48 BRNIY HEADLIGHT 29 GR 22 in 56 cm 38 in 97 cm Reference Point RESISTOR ES MODULE LE SE LEX WIRE END VIEW 6 in s bas 15 cm 4 in SUE ii d 10 cm
26. n Switch Let s opera torchoose the FrontorR ear winch Poweris switched to the Front winch or Rear winch via the switch Infrared IR Light Control Switch if equipped In fra red lightis an optional item that mounts on the front bumper NOTE When thedR light is switched on all other lights headlights amp brake are switched off D enge a bm i i atis d pi Sr FP a C i gt LT 1 y d A 4 Fuel Valve The fuel valve allows the operator to Switch between the front gas tank and rear gas tank located behind the seat It is recommended to use the rear tank first the operator can use the front fuel gauge to view the remaining front tank Front Tank Fuel Valve pm E te zi s E ai a s nd d MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION WINCH OPERATION The Sportsman MV is equipped with two 2500 Ib 2 5ci Warn Winches One winch in the front and one in the rear of the MV Winch Handlebar Controls The winch selection switch located on the left handle bar gives the operator the ability to select the front or rear winch The IN OUT control controls the direction of the cable for the winch IN pulls the cable into the winch and OUT feeds the cable out of the winch Winch Control The winch control located on the side of the winch gives the operator e
27. r 5 in the 2005 consumer version of the Sportsman MV7 Service Manual provided with the unit 2 Slide the tow bar collars overto the nextavailable pin hole on the bumper D POLARIS 5 2 MILITARY USE ONLY MILITARY USE ONLY BODY STEERING SUSPENSION 5 Secure the tow arm to the extension arm am the secure pin Install Pin to Secure Tow Bar Extensiof 3 Secure the tow bar with the same tow bar secure pins Install the pins into the holes so thatthe tow bar collars are on the inside of the tow bar pins db 6 To disassemble the tow bar reverse the setup W lt EA Oud steps above 4 With the tow Dan eXtended secure the tow bar support arm 9 3 ij POLARIS MILITARY USE ONLY INSTALLATION REMOVAL INSTALL 1 5 4 MILITARY USE ONLY BODY STEERING SUSPENSION FRONT ROLL BAR Install the gurney onto the rear rack Be sure the 1 Remove the four bolts each side that gurney mount slides into the mounting bracket on roll bar to the frame gt the rack See photo Secure the gurney with the pin on both sides a ES 8 F 1 oe SS Gurney Installed 2 To install the roll bar install roll bar and reinstall 4 bolts each side Torque bolts to 14 16 ft los 19 22 Nm io POLARIS MILITARY USE ONLY MILITARY USE ONLY BODY STEERING SUSPENSI
28. ration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris Suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealerto resolve any warranty issues Should your dealer require any additional assis tance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any ofthe above terms are void because of state orfederallaw all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be coveredebywarranty MILITARY USE ONLY MILITARY USE ONLY GENERAL INFORMATION CHAPTER 7 LINE RA L Model Identification 1 2 Serial Number Location y 2 Model d 1 2 Specifications Sportsman MV s 1 3 1 4 Publication Numbers 1 5 Paint COUGS NC ea 1 5 Starting the Sportsman MV 1 6 Controls Sportsman MV 35 1 7 Winch Opertaion amp Ww 1 8 NOTICE THIS IS UPDATED INFORMATION USE THIS INFORMATION WITH CHAPTER
Download Pdf Manuals
Related Search