2005 Polaris Sportsman 700/800 EFI Service Manual
Original Polaris Sportsman Service Manual for 700/800 EFI models.
Manual includes high resolution diagrams, images, detailed instruction and technical recommendations and more.
Manual is indexed and searchable.
Part Number: 9919820
Models Covered in this manual:
- 2005 SPORTSMAN 700 EFI
MODEL NUMBER: A05MH68AU
ENGINE MODEL: EH068OLE22
- 2005 SPORTSMAN 800 EFI
MODEL NUMBER: A05MH86AU
ENGINE MODEL: EH076OLE011
- 2005 SPORTSMAN 700 EFI
MODEL NUMBER: A05MH68AU
ENGINE MODEL: EH068OLE
- 2005 SPORTSMAN 800 EFI
MODEL NUMBER: A05MH76AU/AW
ENGINE MODEL: EH076OLE
Manual Chapters:
- General
- Maintenance
- Engine
- Fuel Injection
- Body and Steering
- Clutching
- Final Drive
- Transmission
- Brakes
- Electrical
- Wiring Diagrams
- Index
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Full list of manual chapters:
INTRODUCTION
TABLE OF CONTENTS
CHAPTER 1 GENERAL
Model Identification
Serial Number Location
2005 Sportsman EFI Dimensions
Specifications - Sportsman EFI
Publication Numbers
Paint Codes
Replacement Keys
Standard Torque Specifications
Special Tools
Torque Table
Conversion Table
Tap Drill Charts
Decimal Equivalent Chart
Glossary of Terms
CHAPTER 2-MAINTENANCE
Periodic Maintenance Chart
Component Locations
Lubricant and Maintenance Product Numbers
Special Tools
Lubrication Charts
Front and Rear Gearcase Lubrication
Transmission Lubrication
Throttle Cable Adjustment
Transmission Linkage Inspection
Fuel System
Compression Test
Battery Maintenance
Ignition
Coolant System Maintenance
Radiator Screen Removal
Air Filter Service
Air Box Sediment Tube Service
Breather Filter
PVT Drying and PVT Drain Plug
Oil Change/Filter
Steering and Toe Alignment
Exhaust System Maintenance
Brake System Service
Suspension Service
Controls
Wheel/Tire --Removal/Installation/Inspection
Warn Winch Operation
Cleaning and Storage
800 EFI Exhaust Canister Maintenance
CHAPTER 3-ENGINE
Engine Exploded Views
Exhaust System View / Notes
Special Tools
Piston Identification
Torque Specifications
Engine Fastener Torque Patterns
Engine Service Data
Cooling System Specifications
Cooling System Test
Engine Removal/Installation
Engine Installation Notes
Cylinder Honing
Oil Flow
Rocker Arm/Pushrod Inspection
Cylinder Head Disassembly/Inspection
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Train Exploded View
Engine Head Reassembly
Cylinder Removal
Valve Lifter Removal/Inspection
Piston Removal
Cylinder Inspection
Piston/Rod/Ring Service
Starter Bendix Removal/Inspection
Flywheel/Stator Removal/Inspection
Flywheel/Stator Installation
Engine Crankcase Disassembly/Inspection
Camshaft Inspection
Engine Crankcase Assembly
Troubleshooting
4--Stroke Coolant System Bleeding Procedure
CHAPTER 4-FUEL INJECTION
Special Tools
Service Notes
EFI System Exploded View
Fuel Tank Exploded View
Electronic Fuel Injection System
Operation Overview
Initial Start/Priming Procedure
Electronic Control Unit
Service
Replacement
Fuel Pump/Tank Assembly
Test
Replacement
Fuel Pressure Regulator
Test
Replacement
Fuel Filters
Service
Replacement
Fuel Injectors
Service
Replacement
Crankshaft Position Sensor
Test
Replacement
Temperature / Barometric Air Pressure Sensor
Test (Refer to Diagnostic Software)
Replacement
Throttle Position Sensor
Test
Replacement
TPS Initialization
Engine Temperature Sensor
Test (Refer to Diagnostic Software)
Replacement
Diagnostics using "Blink Codes"
Troubleshooting
CHAPTER 5-BODY AND STEERING
Torque Specifications and Special Tools
Cover/Panel Removal
Side Panel Removal
Front Cover Removal
Footwell Removal/Install
Front Storage Removal/Install
Rear Rack Removal/Install
Front Cab Removal/Install
Rear Cab Removal/Install
Rear Storage Removal/Install
Radiator Screen Removal
Body Assembly, Exploded View
Headlight Pod Exploded View
Handlebar Block Installation Procedure
Steering Assembly, Exploded View
A-Arm Replacement
Rear Suspension Assembly
Strut Assembly Exploded View
Front Strut Cartridge Replacement
Front Strut Ball Joint Replacement
Steering Post Assembly
Decal Replacement
CHAPTER 6-CLUTCHING
Drive Clutch Exploded View
PVT Sealing and Ducting Components
EBS System Exploded View
Special Tools, Supplies and Torques
PVT Operation Overview
PVT Maintenance/Inspection/Drying
PVT Overheating/Diagnosis
PVT Disassembly
PVT Assembly/Inspection
Drive Clutch Spring Specifications
Shift Weights /Inspection
700 Drive Clutch Disassembly/Inspection
700 Drive Clutch Reassembly
Drive Belt Removal/Inspection
Drive Belt Installation
Clutch Alignment/Offset
Drive Clutch Bushing Service
Driven Clutch Service
Driven Clutch Exploded View
Troubleshooting
CHAPTER 7-FINAL DRIVE
Final Drive Torque Specifications
AWD Front Axle Remove/Install
AWD Front CV Joint Boot Replace.
AWD Front Drive Axle Exploded View
Front Hub Disass./Assemble
AWD Front Prop Shaft Removal
U-Joint Disassemble/Assemble
Drive Axle / Propshaft Exploded View
AWD Front Gearcase Operation
AWD Front Gearcase Service
Rear Hub Remove/Install
Rear Hub Disassembly/Assembly
Rear Drive Shaft Removal
Driveshaft / CV Joint Tips
Rear Driveshaft Installation
Rear Driveshaft Service
Rear Gearcase Service
CHAPTER 8-TRANSMISSION
Transmission, Exploded View
Torque Specifications/Lubrication
Gear Shift Selector Removal
Transmission Removal
Transmission Installation
Transmission Disassembly
Transmission Reassembly
CHAPTER 9-BRAKES
Special Tools/Specifications/Torques
Brake System Components
Rear Caliper Exploded View
Front Caliper Exploded View
Rear Auxiliary Master Cylinder Exploded View
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Overview
Hydraulic Caliper Bleeding
Brake Bleeding / Fluid Change
Master Cylinder Removal
Master Cylinder Installation
Front Pad Removal
Front Pad Assembly
Brake Burnishing
Front Disc Inspection
Front Disc Removal/Replacement
Front Caliper Removal
Front Caliper Disassembly
Front Caliper Inspection
Front Caliper Reassembly
Front Caliper Installation
Rear Pad Removal
Rear Pad Installation
Rear Caliper Removal/Inspection
Rear Caliper Reassembly
Rear Disc Inspection
Rear (Auxiliary) Brake Remove/Install
Troubleshooting
CHAPTER 10-ELECTRICAL
Crankshaft Position Sensor Gap
Gear Position Switch Test
Instrument Cluster Overview
Speedometer Removal/Installation
Speedometer Operation Troubleshooting
Coolant Sensor Tests
Fan Motor Tests
Fan Control Switch Tests
Electronic Throttle Circuit System Operation
Flywheel Identification
Ignition System Operation
Ignition Components
Ignition System Troubleshooting
Charging System Testing
Fan / ECU Relays
Charging System Testing Flow Chart
Battery Identification
Conventional Battery Activation/Service
Low Maint. Battery Activation/Service
Head Light/ Lamp / Switch Service
Work / Brake Light Lamp /Switch Service
Fuel Sender Test
Accessory Wire Connections
Winch Wiring Diagram
Starter System Troubleshooting
Starter Motor Service
WIRING DIAGRAMS
INDEX
A-C
D-F
G-M
O-S
T-W
