2005-2006 Polaris Sportsman 700/800 EFI Service & Repair Manual

1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2005-2006 SPORTSMAN 700 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL NUMBER: A05MH68, A06MH68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 2005-2006 SPORTSMAN 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MODEL NUMBER: A05MH76, A06MH76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

1.2 GENERAL INFORMATION MODEL NUMBER INFORMATION MODEL NUMBER The machine model number must be used with any correspondence regarding warranty or service. ENGINE DESIGNATION NUMBERS EHO680LE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start EHO760LE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start VIN IDENTIFICATION TRANSMISSION I.D. LOCATION ENGINE AND MACHINE SERIAL NUMBERS 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. 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). A 06 MH 76 AU 6

1.3 GENERAL INFORMATION 2005-2006 SPORTSMAN 700 EFI MODEL NUMBER: A05MH68, A06MH68 ENGINE MODEL: EHO680LE Table 1-1: Sportsman 700 EFI General Specifications Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm Wheel Base 50.75 in./128.9 cm Dry Weight 770 lbs./326.6 kg Gross Vehicle Weight 1220 lbs. / 553 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Towing Capacity 1500 lbs./680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs./68 kg Optional Wheels Shown

1.4 GENERAL INFORMATION Table 1-2: 2005/2006 700 EFI Specifications Engine Platform Polaris Twin Cylinder Engine Model Number EHO680LE025 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 1150 ± 100 RPM Engine Max Operating Rpm 6500 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 USFS Approved Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 30 micron in Tank - (not replaceable) 10 micron in Line (replaceable) Fuel Injector(s) Bosch EFI Controller Bosh MSE 1.1 ECU Fuel Capacity / Requirement 4.13 gal US / 15.6 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 500 w @ 6000 RPM Lights : Pod 50 watts Grill Two x 27 watts Brake 8.26 watts Tail 26.9 watts Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 13° BTDC @ 1200 RPM Spark plug / Gap RC7YC / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 6 amp Starting Electric Instrument Cluster Analog Speedo w/ LCD Table 1-3: 2005/2006 700 EFI Specifications Drivetrain Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 15 oz. / 445 ml Front Gearcase Capacity 5 oz. / 150 ml Rear Gearcase Capacity 5 oz. / 150 ml Gear Ratio : Low Rev High Front Drive Rear Drive 7.49:1 5.11:1 2.70:1 3.82:1 3.10:1 Clutch Type PVT w/EBS Belt 3211091 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 76 in. / 193 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size / Pattern - Front Steel 26x8-12 / 4-156 Wheel Size / Pattern - Rear Steel 24x11-12 / 4-156 Front Tire Size 24x8-12 Rear Tire Size 24x11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc Table 1-4: A05MH68AU & A06MH68AU Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters (Feet) 0-1800 (0-6000) MY’05: 20-56 (5631215) MY’06: 20-58 (5631216) Blu/Green (7041157) Wht/Yel (3234199) MY’05: 60-56-40 (3234208) MY’06 (3234356) 1800-3700 (6000-12000) MY’05 20-54 (5631214) MY’06 20-56 (5631215) Blu/Green (7041157) Wht/Yel (3234199) 60-56-40 (3234208) MY’06 (3234356)

1.5 GENERAL INFORMATION 2005-2006 SPORTSMAN 800 EFI MODEL NUMBER: A05MH76, A06MH76 ENGINE MODEL: EHO760LE Table 1-5: Sportsman 800 EFI General Specifications Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm Wheel Base 50.75 in./128.9 cm Dry Weight 770 lbs./326.6 kg Gross Vehicle Weight 1220 lbs. / 553 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Towing Capacity 1500 lbs./680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs./68 kg

1.6 GENERAL INFORMATION Table 1-6: 2005/2006 800 EFI Specifications Engine Platform Polaris Twin Cylinder Engine Model Number EHO760LE013 Engine Displacement 760cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 10:1 Compression Pressure 150-200 psi Engine Idle Speed 1150 ± 100 RPM Engine Max Operating Rpm 6500 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 liters Exhaust System Dual Pipe / Silencer Fuel System Fuel System Electronic Fuel Injection Fuel Pump 25L per hour at 39 PSI Fuel Filter(s) 30 micron in Tank - (not replaceable) 10 micron in Line (replaceable) Fuel Injector(s) Bosch EFI Controller Bosch MSE 1.1 ECU Fuel Capacity / Requirement 4.13 gal US / 15.6 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 500 w @ 6000 RPM Lights : Pod 30 watts Grill Two x 27 watts Brake 8.26 watts Tail 26.9 watts Ignition System DC/CDI Ignition Ignition Timing 13°BTDC @ 1200 RPM Spark plug / Gap RC7YC/ .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr Circuit Breakers Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 6 amp Starting Electric Instrument Cluster Analog Speedo w/ LCD Table 1-7: 2005/2006 800 EFI Specifications Drivetrain Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 15 oz. / 450ml Front Gearcase Capacity 5 oz. / 150ml Rear Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 7.49:1 5.11:1 2.70:1 3.82:1 3.10:1 Clutch Type PVT w/EBS Belt 3211106 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 76 in. / 193 cm Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size / Pattern - Front 26x 8 - 12 / 4-156 Wheel Size / Pattern - Rear 26 x 11 - 12 / 4-156 Front Tire Size 26 x 8 - 12 Rear Tire Size 26 x 11 - 12 Recommended Air Pressure Front - 5 psi & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc Table 1-8: A06MH76AU Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters (Feet) 0-1800 (0-6000) MY 05: 20-60 (5631689) MY 06: 20-62 (5631700) Blu/Grn (7041157) Orange (3234233) 3234234 1800-3700 (6000-12000) MY05: 20-58 (5631216) MY 06: 20-60 (5631216) Blu/Grn (7041157) Orange (3234233) 3234234

1.7 GENERAL INFORMATION MISC. NUMBERS/CHARTS PUBLICATIONS PAINT CODES REPLACEMENT KEYS Replacement keys can be made from the original key (Phoenix excluded). 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. Table 1-9: Publications Year Model Model No. Owner's Manual PN Parts Manual PN Parts Micro Fiche PN 2005 Sportsman 700 EFI A05MH68AU 9919426 9919427 9920111 2005 Sportsman 800 EFI A05MH76AU 9917720 9917721 9917722 2006 Sportsman 700 EFI A06MH68AU 9920028 9920022 9920023 2006 Sportsman 800 EFI A06MH68AU 9920028 9920029 9920030 Table 1-10: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman 700/800 EFI Frame Black 9440 P-067 Table 1-11: Key Numbers Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 (Phoenix & Youth Models Excluded) Key Boot PN 5533534

1.8 GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. SPECIAL TOOLS Special took may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657.

1.9 GENERAL INFORMATION CONVERSION TABLE °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: (°F + 40) ÷ 9 - 40 = °C

1.10 GENERAL INFORMATION SAE TAP DRILL SIZES METRIC TAP DRILL SIZES DECIMAL EQUIVALENTS

2005-2006 Polaris Sportsman 700/800 EFI Service & Repair Manual

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