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Sportsman 800 Efi 2005
Polaris Sportsman 800 Efi 2005 Service Manual
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2005 SPORTSMAN 700 EFI
2005 SPORTSMAN 800 EFI
SER
VICE MANUAL
PN 9919820
2005 SPORTSMAN 700/800 EFI SER
VICE MANUAL
PN 9919820
Printed in USA
9919820
PART #
Cvr_9919820 10/14/04 10:19 AM Page 1
2
Table of Contents
General Maintenance
5
Default Chapter
5
Table of Contents
5
Model Identification
6
Serial Number Location
6
Sportsman 800 Efi
7
Specifications
8
Publication Numbers
10
Paint Codes
10
Replacement Keys
10
Standard Torque Specifications
11
Special Tools
11
Torque Table
16
Conversion Table
16
Tap Drill Charts
18
Glossary of Terms
18
Decimal Equivalent Chart
18
Maintenance
19
Periodic Maintenance Chart
20
Maintenance and Lubrication
21
Component Locations
24
Special Tools
26
Front & Rear Gearcase Lubrication
29
Rear Gearcase
30
Transmission Lubrication
31
Throttle Cable
32
Throttle Inspection
32
Compression Test
33
Fuel Filter
33
Battery Maintenance
34
Engine Mounts
34
Spark Plug
35
Ignition Timing
35
Liquid Cooling System
36
Coolant Level
37
Cooling System Hoses
37
Radiator Screen Removal
38
Air Box Sediment Tube Service
39
PVT Drying & PVT Drain Plug
40
Breather Hose
40
Engine Oil Level
41
Oil and Filter Change
42
Camber and Caster
43
Wheel Alignment
44
Toe Alignment
45
Exhaust Pipe
45
Brake Pad Inspection
46
Brake System Inspection
46
Auxiliary Brake
47
Controls
48
Front Suspension
48
Rear Suspension
48
Tire Pressure
49
Wheel Installation
49
Wheel Removal
49
Tire Inspection
50
Warn® Winch Operation
51
Cleaning and Storage
53
Cleaning the Atv
53
800 EFI Exhaust Canister Maintenance
54
Battery Storage
54
Table of Contents
55
Default Chapter
56
Engine Exploded Views
56
Top End
59
Electrical Components
61
Exhaust System
62
Piston Identification
63
Special Tools
63
Torque Specifications
64
Engine Fastener Torque Patterns
65
Engine Service Data
69
Cooling System Specifications
69
Cooling System Test
69
Engine Removal/Installation
71
Engine Installation Notes
71
Cylinder Hone Selection and Honing Procedure
73
Engine Lubrication
73
Honing to Deglaze
73
Oil Pressure Test
73
Cylinder Honing
74
Oil Flow
74
Rocker Arm/Pushrod Inspection
75
Cylinder Head Removal
75
Cylinder Head Disassembly/Inspection
76
Valve Inspection
78
Combustion Chamber
79
Valve Seat Reconditioning
79
Cylinder Head Assembly
81
Cylinder Head Reassembly
81
Valve Sealing Test
82
Valve Train Exploded View
82
Engine Head Reassembly
83
Cylinder Removal
85
Piston Removal
85
Valve Lifter Removal/Inspection
85
Cylinder Inspection
86
Piston/Rod Inspection
88
Piston Ring Installed Gap
89
Piston/Rod/Ring Service
90
Starter Bendix Removal/Inspection
90
Flywheel/Stator Installation
91
Flywheel/Stator Removal/Inspection
91
Engine Crankcase Disassembly/Inspection
92
Cam Gear Disassembly
94
Cam Gear Removal
94
Camshaft Inspection
101
Engine Crankcase Assembly
101
Troubleshooting
113
Cooling System
114
Engine Notes
117
Special Tools
118
Service Notes
119
EFI System Exploded View
120
Efi System Component Locations
121
Fuel Tank Exploded View
123
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
128
Replacement
128
Fuel Injectors
128
Service
129
Replacement
129
Fuel Filters
128
Service
128
Crankshaft Position Sensor
129
Test
130
Replacement
130
Temperature / Barometric Air Pressure Sensor
130
Replacement
131
Throttle Position Sensor
131
Test
131
Replacement
133
Engine Temperature Sensor
133
Diagnostics Using "Blink Codes
134
Troubleshooting
135
Fuel System / Fuel Injection Notes
137
Side Panel Removal
139
Footwell Removal/Install
140
Front Cover Removal
140
Front Storage Removal/Install
141
Rear Rack Removal/Install
143
Front Storage Installation
143
Rear Storage Removal/Install
145
Radiator Screen Removal
146
Body Assembly Exploded View
147
Body Rack Exploded View
148
Headlight Pod Exploded View
149
Handlebar Block Installation Procedure
150
A-Arm Replacement
152
Rear Suspension Assembly
153
Strut Assembly
154
Front Strut Cartridge Replacement
155
Ball Joint Replacement
155
Decal Replacement
156
Steering Post Assembly
156
Clutch
157
Drive Clutch Exploded View
158
PVT Sealing and Ducting Components
158
Special Tools, Supplies & Torques
160
EBS System Exploded View
160
PVT Operation Overview
160
Drive Clutch Operation
160
Driven Clutch Operation
160
Pvt Drying
161
PVT Maintenance/Inspection/Drying 6.5
162
PVT Overheating/Diagnosis
162
PVT Disassembly
163
PVT Assembly/Inspection
164
Drive Clutch Spring Specifications
165
Shift Weights /Inspection
166
Drive Clutch Disassembly/Inspection
167
Spider Removal
168
Drive Clutch Inspection
169
Moveable Sheave Bushing Inspection
170
Drive Clutch Reassembly
171
Drive Belt Removal/Inspection
172
Drive Belt Installation
173
Clutch Alignment/Offset
174
Clutch Offset
174
Bushing Service
175
Removal and Installation
175
Driven Clutch Exploded View
184
Driven Clutch Service
184
Troubleshooting
184
Final Drive
188
Front Hub Assembly
191
Front Hub Disassembly
191
Awd Front Drive Axle Exploded View
194
Rear Hub Installation
206
Rear Hub Assembly
207
Rear Hub Disassembly
207
Driveshaft/CV Joint Handling Tips
208
Rear Drive Shaft Removal
208
Rear Drive Shaft Installation
209
Rear Drive Shaft Service
210
Rear Gearcase Installation
215
Transmission
217
Transmission Exploded View
218
Gear Shift Selector Removal
220
Torque Specifications/Lubrication
220
Transmission Removal
220
Transmission Installation
221
Transmission Disassembly
222
Transmission Reassembly
227
Brakes
233
2005 Sportsman EFI Dimensions
234
Specifications
234
Brake System Components
235
Front Caliper Exploded View
236
Rear Caliper Exploded View
236
Brake Noise Troubleshooting
237
Brake System Service Notes
237
Hydraulic Brake System Overview
238
Brake Bleeding / Fluid Change
239
Hydraulic Caliper Bleeding
239
Master Cylinder Installation
241
Master Cylinder Removal
241
Front Pad Removal
242
Front Pad Assembly
244
Brake Burnishing
245
Front Disc Inspection
245
Front Disc Removal/Replacement
245
Front Caliper Disassembly
246
Front Caliper Removal
246
Front Caliper Inspection
247
Front Caliper Reassembly
247
Front Caliper Installation
248
Rear Pad Installation
250
Rear Caliper Removal/Inspection
251
Rear Caliper Assembly
252
Rear Disc Inspection
253
Troubleshooting
255
Brakes Notes
257
Crankshaft Position Sensor Gap
258
Gear Position Switch Test
258
Instrument Cluster Overview
259
Diagnostic Mode
260
Efi Diagnostic Mode
262
Speedometer Removal/Installation
264
Fan Motor Tests
270
Fan Motor Current Draw
270
Coolant Temperature Sensor
270
Fan Control Circuit Bypass Test
270
Etc Operation Test
271
Flywheel Identification
272
Ignition System Operation
274
Ignition System Troubleshooting
274
Alternator Output Test
275
Charging System Testing Flow Chart
277
Battery Identification
278
Battery Activation
278
Conventional Battery
278
Conventional Battery Installation
279
Conventional Battery Specific Gravity Test
280
Load Test
280
Charging Procedure
281
Off Season Storage
281
Battery Charging
282
Battery Testing
283
Battery Load Test
284
Low Maintenance Battery Charging
284
Bulb Replacement
285
Headlamp Switch Test
288
Fuel Sender Test
290
Brake Light Switch
290
Accessory Wire Connections
291
Starter System Troubleshooting
293
Starter Motor Removal
293
Voltage Drop Test
293
Armature Testing
295
Starter Drive
297
Starter Assembly
298
Starter System Testing Flow Chart
299
4
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Polaris Sportsman 800 Efi 2005 Specifications
General
Brand
Polaris
Model
Sportsman 800 Efi 2005
Category
Offroad Vehicle
Language
English
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