Polaris Sportsman 700 Efi 2005 User manual

2005 SPORTSMAN 700 EFI
2005 SPORTSMAN 800 EFI
SERVICE MANUAL
PN 9919820
2005 SPORTSMAN 700/800 EFI SERVICE MANUAL PN 9919820
Printed in USA
9919820
PART #
Cvr_9919820 10/14/04 10:19 AM Page 1

2005 SPORTSMAN 700/800 EFI
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 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.
Some Polaris factory manuals can be downloaded from www.polarisindustries.com or purchased from
www.purepolaris.com or contact your nearest Polaris dealer.
2005 Sportsman 700/800 EFI ATV Service Manual (PN 9919820)
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:
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
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
Warn, Trademark of the Warn Industries
HiPerWashtand Liquid Bufftare trademarks of HPC inc.

GENERAL
MAINTENANCE
ENGINE
ELECTRONIC FUEL INJECTION
CLUTCHING
FINAL DRIVE
BODY AND STEERING
TRANSMISSION
BRAKES
ELECTRICAL

GENERAL INFORMATION
1.1
Model Identification 1.2.......................
Serial Number Location 1.2...................
2005 Sportsman EFI Dimensions 1.3...........
Specifications - Sportsman EFI 1.4--1.5............
Publication Numbers 1.6.....................
Paint Codes 1.6.............................
Replacement Keys 1.6.......................
Standard Torque Specifications 1.6............
Special Tools 1.7--1.10............................
Torque Table 1.11............................
Conversion Table 1.12........................
Tap Drill Charts 1.13..........................
Decimal Equivalent Chart 1.13.................
Glossary of Terms 1.14........................
Specs