Polaris 2005 Sportsman MV7 User manual

2005 SPORTSMAN MV7
SERVICE MANUAL
PN 9919963
2005 SPORTSMAN MV7SERVICE MANUAL PN 9919963
Printed in USA
9919963
PART #
Cvr_9919963 10/19/04 2:43 PM Page 1

2005 SPORTSMAN MV7
SERVICE 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 2005 Polaris Sportsman MV7ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota
55340.
2005 Sportsman MV7Service Manual (PN 9919963)
ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may
result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX
CHAPTER 1 GENERAL
CHAPTER 2 MAINTENANCE
CHAPTER 3 ENGINE
CHAPTER 4 FUEL SYSTEM
CHAPTER 5 BODY/SUSPENSION
CHAPTER 6 PVT SYSTEM
CHAPTER 7 FINAL DRIVE
CHAPTER 8 TRANSMISSION
CHAPTER 9 BRAKES
CHAPTER 10 ELECTRICAL

GENERAL INFORMATION
1.1
Model Identification 1.2.......................
Serial Number Location 1.2...................
Publications Numbers / Replacement Keys 1.3..
2005 Sportsman MV7/ Dimensions 1.4--1.5.........
Special Tools 1.6--1.10............................
Standard Torque Specifications 1.11............
Conversion Table 1.12........................
Tap Drill Charts 1.13..........................
Decimal Equivalent Chart 1.13.................
Glossary of Terms 1.14........................
Specs

GENERAL INFORMATION
1.2
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
Year Designation Basic Chassis
Designation Engine Designation
A05MH68AP
Emissions &
Model Option
ENGINE DESIGNATION NUMBERS
EH068OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start.................
VIN IDENTIFICATION
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17
4XA MH 68A* 5P0 00 000
Vehicle Description Vehicle Identifier
Powertrain
Engine
Emissions Model
Year
Plant No. Individual Serial No.
Body Style
Check Digit
World Mfg. ID
* This could be either
a number or a letter
ENGINE SERIAL NUMBER LOCATION
Be sure to refer to the engine model number and serial number
whenever corresponding about an engine. This information
can be found on the sticker applied to the top side of the
crankcase (A). An additional number is stamped on the side of
the crankcase beneath the cylinder coolant elbow.
MACHINE MODEL NUMBER AND
SERIAL NUMBER LOCATION
The machine model number and serial number are
important for vehicle identification. The machine serial
number is stamped on the lower left side of the frame
tube.(B)
TRANSMISSION I.D. NUMBER
LOCATION
A
B
Front
The transmission I.D. number is located on
the right side of machine.

GENERAL INFORMATION
1.3
PUBLICATION NUMBERS
Year Model Model
No. Owner’s Manual
PN
Parts
Manual PN Parts Micro
Fiche PN
Warn®
Winch
Guide
2005 Sportsman 700 MV A04MH68 9919959 9919960 9919961 9919934
NOTE: Military MV units utilize a different parts manual. Contact Polaris Industries customer service for the part
number at (763) 417--8650.
NOTE: Some publications can be found at the Polaris website: www.polarisindustries.comor purchased from
www.purepolaris.com.
PAINT CODES
PAINTED PART COLOR
DESCRIPTION DITZLER NUMBER POLARIS NUMBER
Springs Black 9440 P-067
FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.
REPLACEMENT KEYS
Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Should both keys become lost, ignition switch
replacement is required.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
700 ENGINE COLD WEATHER FROST PLUG HEATER
Frost Plug Heater for Sportsman 600/700 -- (PN 2873069)
31XX
Key Series
Number

GENERAL INFORMATION
1.4
MODEL: 2005 SPORTSMAN MV7..........
MODEL NUMBER: A05MH68.
ENGINE MODEL: EH068OLE..
Category Dimension / Capacity
Length 89 in./226 cm
Width 48 in./122 cm
Height 50 in./127 cm
Wheel Base 50.75 in./129 cm
Dry Weight 992 lbs./450 kg
Gross Vehicle Weight 1700 lbs./771 kg
Front Rack Capacity 150 lbs./68 kg
Rear Rack Capacity 300 lbs./136 kg (Rear rack capacity and tongue weight not to
exceed 300 lbs./136 kg)
Towing Capacity 1500 lbs./681 kg
Hitch Tongue Capacity 150 lbs./68 kg
Winch Capacity (Front/
Rear) 2500 lbs (1134 kg) each
Body Style Spirit
2005 SPORTSMAN MV7

GENERAL INFORMATION
1.5
MODEL: 2005 SPORTSMAN MV7..........
MODEL NUMBER: A05MH68.
ENGINE MODEL: EH068OLE..
Engine
Platform Polaris Twin Cylinder
Engine Model Number EH0680LE017
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.78:1
Compression Pressure 150--170 psi
Engine Idle Speed 1200 ±50 RPM
Engine Max Operating Rpm 6000 Rpm ±200 Rpm
Cooling System / Capacity Liquid -- 3.2 qt / 3 ltr
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Wet Sump
Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr
Exhaust System Single Pipe
Carburetion
Carburetor model Mikuni BST 34mm
Main Jet 157.5
Pilot Jet 45
Pilot Air Jet 160
Jet Needle -- Clip Position 4HB41--4
Needle Jet P--6 (829)
Pilot Screw Initial Setting 1.5 Turns Out (Ini-
tial starting point, setting may
vary)
Float Height 13 mm ±1 / 0.51 in ±0.04
Fuel Delivery Fuel Pump
Fuel Capacity / Requirement Front -- 4.25 gal US / 16 ltr
Rear -- 4.0 gal US / 15 ltr
87 Octane (minimum)
89 Oxygenated
Electrical
Alternator Output 330 w @ 3000 RPM
Voltage Regulator 3--Phase -- Sure Power
Lights : Pod 50 watts
Grill Two x 37 watts
Brake Two x 8.26 watts
Tail Twox26.9watts
Ignition System DC/CDI Ignition
Ignition Timing 13°BTDC @ 1200 RPM
Spark plug / Gap RC7YC/ .035 in./0.9 mm
Battery / Model / Amp Hr 30 Amp Hr
Starting Electric / Recoil Backup
Instrument Cluster LCD
Drivetrain
Transmission Type Drumshift -- H/L/N/Rev/Park
Transmission Capacity 15.2 oz. / 450m
Rear Gearcase Capacity 10 oz. / 300ml
Front Gearcase Capacity 5 oz. / 150ml
Gear Ratio : Low
Rev
High
Front Drive
Rear Drive
7.5:1
5.11:1
2.89:1
3.82:1
3.10:1
Clutch Type PVT w/EBS
Belt 3211091
Steering / Suspension
Front Suspension / Shock A--arm / MacPherson Strut
Front Travel 8.2in./21cm
Rear Suspension / Shock Progressive Rate Independent
/Two x 2” Coil--over Shock
Rear Travel 9.5 in. / 24.13 cm
Ground Clearance 10.5 in. / 26.7 cm
Shock Preload Adjustment
Front / Rear Front --Non Adjustable. Rear -- Ratchet Style-- Std.
Turning Radius 71.5 in. / 181.6 cm unloaded
Toe Out 0 -- 1/16 in / .0 -- .159 mm
Wheels / Brakes
Wheel Size / Pattern -- Front 25x8--12 / 4--156
Wheel Size / Pattern -- Rear 25x10--12 / 4--156
Recommended Air Pressure
F/R 5 psi Front 5 psi Rear
Brake -- Front Dual Hydraulic Disc
Brake -- Rear Dual Hydraulic Disc
JETTING CHART
Altitude
Meters
(Feet)
AMBIENT TEMPERATURE
0--1800
(0--6000)
above 1800
(above 6000)
Below 40°F
Below 5°C
162.5 157.5
155 150
(7041157)
(7041635)
(7041635)
(5132751)
(5132751)
(5631215)
(5631214)
(7041157)
CLUTCH CHART EBS Models have no helix/spring adjustment
Altitude
Meters
(Feet)
0--1800
(0--6000)
1800--3700
(6000--12000)
Shift Drive
Spring
Driven
Helix
Weight
20--56
20--54
EBS
41--37
Blu/Grn
Blu/Grn
Driven
Spring
Wht/ Yel
Wht/ Yel EBS
41--37
Above +40°F
Above +5°C

GENERAL INFORMATION
1.6
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
PV--43527 Oil Filter Wrench 2,3
2870872 Shock Spanner Wrench 2, 5
8712100 or 8712500 Tachometer 2,10
2200634 Valve Seat Reconditioning Kit 3
PU--45257 Valve Spring Compressor 3
2871043 Flywheel Puller 3
2870390 Piston Support Block 3
PU--45497--2 Cam Gear Tooth Alignment Tool 3
PU--45497--1 Cam Gear Spring Installation Kit (3 Tapered Pins) 3
PU--45498 Cam Spanner Wrench 3
PU--45838 Gear Holder 3
PA--44995 Water Pump Mechanical Seal Installer 3
PU--45543 Universal Drive Handle 3
PU--45483 Main Seal Installer 3
PU--45658 Main Crankshaft Seal Saver 3
PA--45401 Water Pump Seal Saver 3
PU--45778 OIl System Priming Tool 3
2870975 Mity VactPressure Test Tool 3, 4, 9
2872314 Carburetor Float Adjustment Tool 4
2870871 Ball Joint Replacement Tool 5
2870623 Shock Absorber Spring Compression Tool 5
2871572 Strut Rod Wrench 5
2871573 LH Strut Spring Compressor 5
2871574 RH Strut Spring Compressor 5
7052069 Charging Needle 5
2200421 Gas Shock Recharging Kit 5
2871352 Shock Rod Holding Tool 5
2871351 FoxtShock IFP Depth Tool 5
2870506 Clutch Puller 6
9314177 Clutch Holding Wrench 6
2871358 Clutch Holding Fixture 6
2870341 Drive Clutch Spider Removal and Install Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing Replacement Tool Kit 6
2870386 Piston Pin Puller 6
2872292 EBS Clutch Alignment Tool 6
2201379 EBS Bushing Replacement Kit 6
8700220 Clutch Compression Tool 6
2871025 Clutch Bushing Replacement Tool Kit 6
2872608 Roller Pin Removal Tool 7
8700226 CV Boot Clamp Pliers 7
PV--43568 Fluket77 Digital Multimeter 10
2870630 Timing Light 10
2870836 Battery Hydrometer 10
*Special Tools Can be ordered through SPX Corporation (1--800--328--6657).