2005 Polaris ATV Sportsman 700 EFI & Sportsman 800 EFI Service & Repair Manual

- www.instant-manuals.com - GENERAL MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL

- www.instant-manuals.com - 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

- www.instant-manuals.com - GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION 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 A 05 MH 68 AU Emissions & Model Option ENGINE DESIGNATION NUMBERS EH068OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ................. EH076OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ................. VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A M H 6 8 A * 4 P 0 0 0 0 0 0 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 LOCA TION 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 LOCA TION 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 LOCA TION A B Front The transmission I.D. number is located on the right side of machine.

- www.instant-manuals.com - GENERAL INFORMATION 1.3 MODEL: 2005 SPORTSMAN 700 EFI .......... MODEL NUMBER: A05MH68AU . ENGINE MODEL: EH068OLE22 .. 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./454 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Spirit MODEL: 2005 SPORTSMAN 800 EFI .......... MODEL NUMBER: A05MH86AU . ENGINE MODEL: EH076OLE011 .. 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./454 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Spirit

- www.instant-manuals.com - GENERAL INFORMATION 1.4 MODEL: 2005 SPORTSMAN 700 EFI .......... MODEL NUMBER: A05MH68AU . ENGINE MODEL: EH068OLE .. Engine Platform Polaris Twin Cylinder Engine Model Number EH0680LE022 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 Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 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 ltr 87 Octane (minimum) 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 Ignition System DC/CDI Ignition Operating RPM 6000 RPM Ignition Timing 13° BTDC @ 1200 RPM Spark plug / Gap RC7YC/ .035 in./ 0.9 mm Battery / Model / Amp Hr Lead Acid / 30 Amp Hr Circuit Breakers Fan 20 amp -- Harness 20 amp Fuel pump/ECU 15 amp Instrument Cluster / Voltage Regulator 6 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 15 oz. / 450m Rear Gearcase Capacity 5 oz. / 150ml Front 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 3211091 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent /Two x 2” 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 -- RatchetStyle-- Std. Turning Radius 76 in. / 193 cm unloaded Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 25x8--12 / 4--156 (205/80R--12) Wheel Size / Pattern -- Rear Steel 25x11--12 / 4--156 (270/60R--12) Front Tire Size 25x8--12 Rear Tire Size 25x11--12 Recommended Air Pressure F/R 5 psi Front 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc (7041157) (3234199) (3234208) (3234208) (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 60--56--40 Blu/Green Blu/Green Driven Spring White 60--56--40 (3234199) White

- www.instant-manuals.com - GENERAL INFORMATION 1.5 MODEL: 2005 SPORTSMAN 800 EFI .......... MODEL NUMBER: A05MH76AU/AW . ENGINE MODEL: EH076OLE .. Engine Platform Polaris Twin Cylinder Engine Model Number EH0760LE011 Engine Displacement 760cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 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 ltr Exhaust System Dual Pipe / Silencer Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 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 ltr 87 Octane (minimum) 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 Ignition System DC/CDI Ignition Operating RPM 6000 RPM Ignition Timing 13° BTDC @ 1200 RPM Spark plug / Gap RC7YC/ .035 in./ 0.9 mm Battery / Model / Amp Hr Lead Acid / 30 Amp Hr Circuit Breakers Fan 20 amp -- Harness 20 amp Fuel pump/ECU 15 amp Instrument Cluster / Voltage Regulator 6 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 15 oz. / 450m Rear Gearcase Capacity 5 oz. / 150ml Front 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 6.7 in. / 17.02 cm Rear Suspension / Shock Progressive Rate Independent /Two x 2” 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 -- RatchetStyle-- Std. Turning Radius 76 in. / 193 cm unloaded Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Cast Alum. 26x8--12 / 4--156 (205/80R--12) Wheel Size / Pattern -- Rear Cast Alum. 26x11--12 / 4--156 (270/60R--12) Front Tire Size 26x8--12 Rear Tire Size 26x11--12 Recommended Air Pressure F/R 5 psi Front 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc (7041157) 3234233 3234234 3234234 (5631689) (5631216) (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--60 20--58 Blu/Green Blu/Green Driven Spring 3234233

- www.instant-manuals.com - GENERAL INFORMATION 1.6 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2005 Sportsman 700 EFI A05MH68AU 9919426 9919427 9919428 2005 Sportsman 800 EFI A05MH76AU 9917720 9917721 9917722 *When ordering service parts be sure to use the correct parts manual. NOTE: Some Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. PAINT CODES PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Frame Black 9440 P-067 FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. Order direct at www.polarisdealers.com (dealers only). 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 WEA THER FROST PLUG HEA TER Frost Plug Heater for Sportsman 700/800 -- (PN 2873069) 31XX Key Series Number

- www.instant-manuals.com - GENERAL INFORMATION 1.7 SPECIAL T OOLS Special Tools maybe required while servicing your machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine T ools PU--45432 -- Caliperor A Basic Caliper Basic Micrometer 2871043 -- Flywheel Puller 2870773 -- C--Clip InstallTool 2870386 -- Piston Pin Puller 2871445 -- Piston Pin Puller Adapter Standard Tools and Engine T ools 2870390 -- Piston Support Block PV--43527 Oil Filter Wrench PA--44995 -- Water Pump Mechanical Seal Install Tool PU--45543 -- Universal Driver Handle PA--45483 -- Main SealInstaller PA--45658 -- Main Crank SealSaver PA--45401 -- Water Pump SealSaver PU--45778 -- OilPump Priming Tool

- www.instant-manuals.com - GENERAL INFORMATION 1.8 SPECIAL T OOLS Standard Tools and Engine T ools 2870303 -- Hone Kit 2870305 -- Stone Replacement Kit 2870459 -- Dial Indicator 2870588 -- Hone Oil (12 oz.) PV--35667--A -- CylinderLeak down Tester 2200634 -- ValveSeat Reconditioning Kit Clutch (PVT) T ools 2870506 -- Drive Clutch Puller 2870913 -- Driven Clutch Puller 2872292 -- EBSClutch Align Tool 9914177--A -- Drive Clutch Holding Tool 8700220 -- Clutch Compression Tool 2871358 -- Clutch Hold Fixture 2870341 -- Drive Clutch Spider Removal Tool

- www.instant-manuals.com - GENERAL INFORMATION 1.9 Clutch (PVT) T ools 2870910 -- RollPin Tool 2871226 -- Clutch Bushing Replacement Kit 2201379 -- EBS Bushing Replacement Kit 2870338 -- Spider Nut Socket 2871358 -- Clutch Holding Fixture 2871025 -- Clutch Bushing Replace Tool Kit Suspension T ools 2870871 -- ATV Ball Joint Tool Kit 2871071 -- Shock Body Holding Tool 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench 2871573 & 2871574 -- Strut Spring Compressor 8700225 & 8700226 -- CV Boot Clamp Pliers

2005 Polaris ATV Sportsman 700 EFI & Sportsman 800 EFI Service & Repair Manual

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