Polaris Sportsman 700/800 EFI Repair Service Manual 2005

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This workshop repair service manual PDF download for the 2005 Polaris Sportsman 700/800 EFI has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

MODEL: 2005 SPORTSMAN 700 EFI
MODEL NUMBER: A05MH68AU
ENGINE MODEL: EH068OLE22

MODEL: 2005 SPORTSMAN 800 EFI
MODEL NUMBER: A05MH86AU
ENGINE MODEL: EH076OLE011


TABLE OF CONTENTS :

CHAPTER 1 GENERAL
CHAPTER 2-MAINTENANCE
CHAPTER 3-ENGINE
CHAPTER 4-FUEL INJECTION
CHAPTER 5-BODY AND STEERING
CHAPTER 6-CLUTCHING
CHAPTER 7-FINAL DRIVE
CHAPTER 8-TRANSMISSION
CHAPTER 9-BRAKES
CHAPTER 10-ELECTRICAL
WIRING DIAGRAMS
INDEX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9919820
Total Pages : 309


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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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 & 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 & 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 & 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

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