2005 Polaris Sportsman 700 EFI & 800 Service Manual
9919820 to the manual 70b01de9-80ac-4f99-8f48-d12a1f757a9e
User Manual: 2005 Polaris Sportsman 700 EFI & 800 EFI Service Manual
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Page Count: 309 [warning: Documents this large are best viewed by clicking the View PDF Link!]
- INTRODUCTION
- TABLE OF CONTENTS
- CHAPTER 1 GENERAL
- 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
- Electronic Control Unit
- Fuel Pump/Tank Assembly
- Fuel Pressure Regulator
- Fuel Filters
- Fuel Injectors
- Crankshaft Position Sensor
- Temperature / Barometric Air Pressure Sensor
- Throttle Position Sensor
- Engine Temperature Sensor
- 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
- 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