2005 POLARIS ATV SPORTSMAN 700 & 800 Efi DIY Factory Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:309
DOWNLOADABLE:YES
FILE TYPE:PDF
VIDEO PREVIEW OF THE MANUAL:
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
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
Vincenzo Colton –
Slow Download speed!!
Talon Camilo –
Quick turn around on the purchase and tech support request.