2005 POLARIS ATV SPORTSMAN 700 & 800 Efi DIY Factory Service Repair Manual – PDF DOWNLOAD

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2005 POLARIS ATV SPORTSMAN 700 & 800 Efi DIY Factory Service Repair Manual

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2005 POLARIS ATV SPORTSMAN 700 & 800 EFI DIY FACTORY SERVICE REPAIR MANUAL – PDF DOWNLOAD:

DESCRIPTION:

2005 POLARIS ATV SPORTSMAN 700 & 800 Efi DIY Factory Service Repair Manual

FOREWORD:

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.

• Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
• This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for Polaris Sportsman 700/800 EFI ATVs. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

TABLE OF CONTENTS:

2005 POLARIS ATV SPORTSMAN 700 & 800 Efi DIY Factory Service Repair Manual

INTRODUCTION........................................  2
TABLE OF CONTENTS...................................  4
CHAPTER 1 GENERAL...................................  5
	Model Identification............................  6
	Serial Number Location..........................  6
	2005 Sportsman EFI Dimensions...................  7
	Specifications - Sportsman EFI..................  8
	Publication Numbers............................. 10
	Paint Codes..................................... 10
	Replacement Keys................................ 10
	Standard Torque Specifications.................. 15
	Special Tools................................... 11
	Torque Table.................................... 15
	Conversion Table................................ 16
	Tap Drill Charts................................ 17
	Decimal Equivalent Chart........................ 17
	Glossary of Terms............................... 18
CHAPTER 2-MAINTENANCE............................... 19
	Periodic Maintenance Chart...................... 20
	Component Locations............................. 24
	Lubricant and Maintenance Product Numbers....... 25
	Special Tools................................... 26
	Lubrication Charts.............................. 27
	Front & Rear Gearcase Lubrication............... 29
	Transmission Lubrication........................ 31
	Throttle Cable Adjustment....................... 32
	Transmission Linkage Inspection................. 33
	Fuel System..................................... 33
	Compression Test................................ 33
	Battery Maintenance............................. 34
	Ignition........................................ 35
	Coolant System Maintenance...................... 36
	Radiator Screen Removal......................... 38
	Air Filter Service.............................. 38
	Air Box Sediment Tube Service................... 39
	Breather Filter................................. 39
	PVT Drying & PVT Drain Plug..................... 40
	Oil Change/Filter............................... 41
	Steering and Toe Alignment...................... 43
	Exhaust System Maintenance...................... 45
	Brake System Service............................ 46
	Suspension Service.............................. 47
	Controls........................................ 48
	Wheel/Tire --Removal/Installation/Inspection.... 49
	Warn® Winch Operation........................... 51
	Cleaning and Storage............................ 53
	800 EFI Exhaust Canister Maintenance............ 54
CHAPTER 3-ENGINE.................................... 55
	Engine Exploded Views........................... 56
	Exhaust System View / Notes..................... 62
	Special Tools................................... 63
	Piston Identification........................... 63
	Torque Specifications........................... 64
	Engine Fastener Torque Patterns................. 65
	Engine Service Data............................. 66
	Cooling System Specifications................... 69
	Cooling System Test............................. 69
	Engine Removal/Installation..................... 70
	Engine Installation Notes....................... 71
	Cylinder Honing................................. 73
	Oil Flow........................................ 74
	Rocker Arm/Pushrod Inspection................... 75
	Cylinder Head Disassembly/Inspection............ 76
	Valve Inspection................................ 78
	Combustion Chamber.............................. 79
	Valve Seat Reconditioning....................... 79
	Cylinder Head Assembly.......................... 81
	Valve Sealing Test.............................. 82
	Valve Train Exploded View....................... 82
	Engine Head Reassembly.......................... 83
	Cylinder Removal................................ 85
	Valve Lifter Removal/Inspection................. 85
	Piston Removal.................................. 85
	Cylinder Inspection............................. 86
	Piston/Rod/Ring Service......................... 87
	Starter Bendix Removal/Inspection............... 90
	Flywheel/Stator Removal/Inspection.............. 91
	Flywheel/Stator Installation.................... 91
	Engine Crankcase Disassembly/Inspection......... 92
	Camshaft Inspection.............................101
	Engine Crankcase Assembly.......................101
	Troubleshooting.................................113
	4--Stroke Coolant System Bleeding Procedure.....115
CHAPTER 4-FUEL INJECTION............................117
	Special Tools...................................118
	Service Notes...................................119
	EFI System Exploded View........................120
	Fuel Tank Exploded View.........................122
	Electronic Fuel Injection System................123
		Operation Overview..........................123
		Initial Start/Priming Procedure.............123
	Electronic Control Unit.........................124
		Service.....................................124
		Replacement.................................124
	Fuel Pump/Tank Assembly.........................125
		Test........................................125
		Replacement.................................126
	Fuel Pressure Regulator.........................127
		Test........................................127
		Replacement.................................127
	Fuel Filters....................................128
		Service.....................................128
		Replacement.................................128
	Fuel Injectors..................................128
		Service.....................................129
		Replacement.................................129
	Crankshaft Position Sensor......................129
		Test........................................129
		Replacement.................................129
	Temperature / Barometric Air Pressure Sensor....130
		Test (Refer to Diagnostic Software).........130
		Replacement.................................130
	Throttle Position Sensor........................131
		Test........................................130
		Replacement.................................131
		TPS Initialization..........................131
	Engine Temperature Sensor.......................133
		Test (Refer to Diagnostic Software).........133
		Replacement.................................133
	Diagnostics using “Blink Codes”.................134
	Troubleshooting.................................135
CHAPTER 5-BODY AND STEERING.........................137
	Torque Specifications and Special Tools.........138
	Cover/Panel Removal.............................138
	Side Panel Removal..............................139
	Front Cover Removal.............................140
	Footwell Removal/Install........................140
	Front Storage Removal/Install...................141
	Rear Rack Removal/Install.......................143
	Front Cab Removal/Install.......................144
	Rear Cab Removal/Install........................145
	Rear Storage Removal/Install....................145
	Radiator Screen Removal.........................146
	Body Assembly, Exploded View....................147
	Headlight Pod Exploded View.....................149
	Handlebar Block Installation Procedure..........150
	Steering Assembly, Exploded View................151
	A-Arm Replacement...............................152
	Rear Suspension Assembly........................153
	Strut Assembly Exploded View....................154
	Front Strut Cartridge Replacement...............155
	Front Strut Ball Joint Replacement..............155
	Steering Post Assembly..........................156
	Decal Replacement...............................156
CHAPTER 6-CLUTCHING.................................157
	Drive Clutch Exploded View......................158
	PVT Sealing and Ducting Components..............158
	EBS System Exploded View........................159
	Special Tools, Supplies & Torques...............160
	PVT Operation Overview..........................160
	PVT Maintenance/Inspection/Drying...............161
	PVT Overheating/Diagnosis.......................162
	PVT Disassembly.................................163
	PVT Assembly/Inspection.........................164
	Drive Clutch Spring Specifications..............165
	Shift Weights /Inspection.......................166
	700 Drive Clutch Disassembly/Inspection.........167
	700 Drive Clutch Reassembly.....................171
	Drive Belt Removal/Inspection...................172
	Drive Belt Installation.........................173
	Clutch Alignment/Offset.........................174
	Drive Clutch Bushing Service....................175
	Driven Clutch Service...........................177
	Driven Clutch Exploded View.....................183
	Troubleshooting.................................184
CHAPTER 7-FINAL DRIVE...............................187
	Final Drive Torque Specifications...............188
	AWD Front Axle Remove/Install...................188
	AWD Front CV Joint Boot Replace.................190
	AWD Front Drive Axle Exploded View..............194
	Front Hub Disass./Assemble......................191
	AWD Front Prop Shaft Removal....................192
	U-Joint Disassemble/Assemble....................192
	Drive Axle / Propshaft Exploded View............194
	AWD Front Gearcase Operation....................195
	AWD Front Gearcase Service......................195
	Rear Hub Remove/Install.........................205
	Rear Hub Disassembly/Assembly...................207
	Rear Drive Shaft Removal........................208
	Driveshaft / CV Joint Tips......................208
	Rear Driveshaft Installation....................209
	Rear Driveshaft Service.........................210
	Rear Gearcase Service...........................212
CHAPTER 8-TRANSMISSION..............................217
	Transmission, Exploded View.....................218
	Torque Specifications/Lubrication...............220
	Gear Shift Selector Removal.....................220
	Transmission Removal............................220
	Transmission Installation.......................223
	Transmission Disassembly........................222
	Transmission Reassembly.........................229
CHAPTER 9-BRAKES....................................233
	Special Tools/Specifications/Torques............234
	Brake System Components.........................235
	Rear Caliper Exploded View......................236
	Front Caliper Exploded View.....................236
	Rear Auxiliary Master Cylinder Exploded View....237
	Brake System Service Notes......................237
	Brake Noise Troubleshooting.....................237
	Hydraulic Brake System Overview.................238
	Hydraulic Caliper Bleeding......................239
	Brake Bleeding / Fluid Change...................239
	Master Cylinder Removal.........................241
	Master Cylinder Installation....................241
	Front Pad Removal...............................242
	Front Pad Assembly..............................244
	Brake Burnishing................................245
	Front Disc Inspection...........................245
	Front Disc Removal/Replacement..................245
	Front Caliper Removal...........................246
	Front Caliper Disassembly.......................246
	Front Caliper Inspection........................247
	Front Caliper Reassembly........................247
	Front Caliper Installation......................248
	Rear Pad Removal................................249
	Rear Pad Installation...........................250
	Rear Caliper Removal/Inspection.................251
	Rear Caliper Reassembly.........................252
	Rear Disc Inspection............................253
	Rear (Auxiliary) Brake Remove/Install...........254
	Troubleshooting.................................255
CHAPTER 10-ELECTRICAL...............................257
	Crankshaft Position Sensor Gap..................258
	Gear Position Switch Test.......................258
	Instrument Cluster Overview.....................259
	Speedometer Removal/Installation................264
	Speedometer Operation Troubleshooting...........265
	Coolant Sensor Tests............................270
	Fan Motor Tests.................................270
	Fan Control Switch Tests........................270
	Electronic Throttle Circuit System Operation....271
	Flywheel Identification.........................272
	Ignition System Operation.......................272
	Ignition Components.............................273
	Ignition System Troubleshooting.................274
	Charging System Testing.........................275
	Fan / ECU Relays................................276
	Charging System Testing Flow Chart..............277
	Battery Identification..........................278
	Conventional Battery Activation/Service.........278
	Low Maint. Battery Activation/Service...........280
	Head Light/ Lamp / Switch Service...............285
	Work / Brake Light Lamp /Switch Service.........288
	Fuel Sender Test................................290
	Accessory Wire Connections......................291
	Winch Wiring Diagram............................292
	Starter System Troubleshooting..................293
	Starter Motor Service...........................293
WIRING DIAGRAMS.....................................301
INDEX...............................................303
	A-C.............................................303
	D-F.............................................304
	G-M.............................................305
	O-S.............................................306
	T-W.............................................307

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