POLARIS SPORTSMAN 800 TWIN EFI ATV Parts Manual Catalog

PARTS MANUAL PN 9917721 and MICROFICHE PN 9917722 10/04 E 2004 Polaris Sales Inc. SPORTSMAN 800 EFI Model #A05MH76AC SPORTSMAN 800 EFI Model #A05MH76AU SPORTSMAN 800 EFI Model #A05MH76AW

TABLE OF CONTENTS SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Parts Manual A A--ARM C7 ......................... AIR BOX B3 ........................ B BRAKE LINES, FRONT B7 ............. BRAKE, FRONT B6 ................... BUMPER MOUNTING A7-8 ............... C CAB, FRONT A5 ..................... CAB, REAR A3-4 ...................... CALIPER, REAR B8 .................. CLUTCH COVER C12 .................. CONTROLS B5 ...................... CONTROLS -- THROTTLE ASM./CABLE B10 . COOLING SYSTEM A13-14 ................ CRANKCASE D11-12 ..................... CRANKSHAFT D11-12 .................... CYLINDER D14 ....................... D DECALS A10-11 ........................ DIPSTICK E3 ........................ DRIVE CLUTCH C10 ................... DRIVE SHAFT, FRONT B11 .............. DRIVE SHAFT, REAR B12 ............... DRIVEN CLUTCH C11 .................. E ELECTRICAL D3--4 ..................... ENGINE MOUNTING B1-2 ................ EXHAUST SYSTEM A12 ................ F FOOT PEDAL B9 ..................... FUEL INJECTOR E5 .................. FUEL TANK B4 ...................... G GEAR SELECTOR C9 ................. GEARCASE D7-8 ...................... GEARCASE MOUNTING, REAR D10 ....... GEARCASE, REAR D9 ................. H HANDLEBAR C1-2 ..................... H HEADLIGHT POD C1--2 .................. HEADLIGHTS C6 ..................... HOUSING, FRONT D6 ................. I INTAKE E2 ......................... M MAGNETO E6 ....................... MANIFOLD D13 ....................... MASTER CYLINDER, REAR B9 .......... O OIL FILTER E3 ...................... OIL PUMP E4 ....................... P PISTON D14 ......................... PROP SHAFT, FRONT B13 .............. PROP SHAFT, REAR B14 ............... R RACK MOUNTING, REAR A6 ........... S SEAT A3-4 ........................... STARTING MOTOR E7 ................. STEERING POST C8 .................. STORAGE BOX, REAR A9 ............. STORAGE, FRONT A8 ................. STORAGE, FRONT A7 ................ STRUT MOUNTING C7 ................ STRUT, FRONT C3 ................... SUSPENSION, REAR D1-2 ............... T TAILLAMPS C6 ...................... THERMOSTAT D13 .................... THROTTLE BODY MOUNTING E1 ........ TOOL KIT E8 ........................ TRANSMISSION MOUNTING D5 ......... W WATER PUMP E4 .................... WHEEL, FRONT C4-5 ................... WHEEL, REAR C13-14 .................... WORKLAMPS C6 .................... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3 CAB, REAR and SEAT SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 6 5 7 8 25 24 28 26 27 30 13 17 16 3 15 14 18 10 12 E 2004 Polaris Sales Inc. 9 4 1 2 11 29 12 11 11 23 20 22 19 19 21

A4 CAB, REAR and SEAT SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512095 2 Screw 2 7555798 2 Washer 3 7512026 3 Screw 4 7556034 3 Washer 5 5246076 1 Retainer, Seat Latch 6 7511930 2 Screw 7 7555792 2 Washer 8 7541925 2 Nut, Nylok 9 5435664-455 5435363-177 5436108-177 5435363-070 5436108-070 1 1 1 1 1 Cab, Rear, NBU Camo (AC)(If built before 7/28/04) Cab, Rear, Black Metallic (AU)(If built before 7/28/04) Cab, Rear, Black Metallic (AU)(If built after 7/28/04) Cab, Rear, Black (AW)(If built before 7/28/04) Cab, Rear, Black (AW)(If built after 7/28/04) 10 7170509 1 Decal, Hitch 11 7661855 14 Rivet 12 5435354-070 5435355-070 1 1 Footwell, Black, LH Footwell, Black, RH 13 7517230 8 Screw 14 7542122 8 Nut, Nylok 15 5812703 1 Foil, Rear Cab, Front, Top 16 5812702 1 Foil, Rear, Cab, Front, Bottom 17 5812701 1 Foil, Cab, Rear 18 1014951-067 1 Frame, Main, Black 19 7515399 4 Screw 20 5245767-067 1 Bracket, Bumper, Lower, Black 21 7542153 6 Nut, Nylok, Flange 22 7512283 6 Screw 23 5244751-067 1 Brace, Support, Frame, Front, Black, LH 24 7621403 2 Rivet 25 5211033 2 Bracket, Lever Retainer 26 7041370 1 Spring, Latch 27 2683661-070 2683433-070 2683434-070 1 1 1 Asm., Seat, Black (AC) Asm., Seat, Black (AW)(AU) Covering, Seat, Black 28 1040387 1 Latch, Seat 29 5412623 2 Grommet, Rubber Mount 30 7172921 1 Decal, Filter Cleaning 10/04

A5 CAB, FRONT SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 1 10 2 5 6 12 3 4 11 8 9 7 E 2004 Polaris Sales Inc. 7 11 5 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5435668-455 5435352-177 5435352-070 1 1 1 Cover, Front, NBU Camo (AC) Cover, Front, Black Metallic (AU) Cover, Front, Black (AW) 2 2632975-455 2632864-177 2632864-070 1 1 1 Asm., Cab, Front, NBU Camo (AC) Asm., Cab, Front, Black Metallic (AU) Asm., Cab, Front, Black (AW) 3 7670057 2 Nut, Speed 4 7517219 2 Screw 5 5435919-455 2633048-455 5435506-293 2632936-293 5435559-473 2632936-473 1 1 1 1 1 1 Panel, Side, NBU Camo, LH (AC) Asm., Panel/Foil, NBU Camo, RH (AC) Panel, Side, Indy Red, RH (AW) Asm., Panel/Foil, Indy Red, RH (AW) Panel, Side, Silver Venom, LH (AU) Asm., Panel/Foil, Silver Venom, RH (AU) 6 5812615 1 Foil, RH 7 7517386 4 Screw 8 5248100 1 Guard, Splash, RH 9 5246872 1 Guard, Splash, LH 10 7661855 2 Rivet 11 7512026 8 Screw 12 7556034 4 Washer 10/04

A6 RACK MOUNTING, REAR SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 7 15 16 17 14 4 9 2 E 2004 Polaris Sales Inc. 3 12 8 13 11 18 10 19 12 15 1 5 6 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517230 4 Screw 2 7517983 2 Screw 3 5248469-418 1 Channel, Rear Rack, Flat Black Wrinkle 4 7518418 2 Screw 5 1014768-418 1 Extender, Rear Rack 6 7517208 6 Screw 7 2632867-070 1 Asm., Rack, Rear, Flat Black Wrinkle (Incl. Warning Decal and Reflectors) 8 7518213 2 Screw 9 5435959 2 Spacer 10 7555843 2 Washer, Flat 11 7542324 2 Nut, Nylok 12 5248471-418 2 Channel, Rear Rack, Front, Flat Black Wrinkle 13 5334092 2 Spacer 14 1014668-067 1 Support, Rear Rack, Black 15 7518341 4 Bolt, Flange 16 ------- 1 Bracket, Silencer, Frame (See Ex- haust System Pg. A12, Ref. 6) 17 7542343 4 Nut, Flange 18 7542153 4 Nut, Nylok, Flange 19 7518424 2 Screw 8/04

A7 STORAGE, FRONT and BUMPER MOUNTING SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 21 2 22 28 10 11 20 5 14 13 1 12 18 10 1 4 15 3 19 34 E 2004 Polaris Sales Inc. 27 23 9 24 29 8 32 7 31 26 6 35 33 2 3 9 1 17 30 25 16 31

A8 STORAGE, FRONT and BUMPER MOUNTING SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7515399 6 Screw 2 1014591-067 1014592-067 1 1 Support, Rack, Black, LH Support, Rack, Black, RH 3 7518341 2 Bolt, Flange 4 7542343 2 Nut, Flange 5 1014635-067 1 Guard, Brush, Black 6 5435629 1 Cover, Radiator 7 7081241 7081242 1 1 Latch, LH Latch, RH 8 7512076 4 Screw 9 5334257 2 Latch, Wire 10 5434314 5434315 1 1 Shield, Side, Radiator, LH Shield, Side, Radiator, RH 11 7661855 6 Rivet 12 5412504 4 Grommet, Rubber Mount 13 5435046 1 Cover, Radiator 14 5247507-067 1 Grill, Brush Guard, Black 15 7518046 4 Screw 16 7172687 7172688 1 1 Decal, Amber Reflector, LH Decal, Amber Reflector, RH 17 5435701 5435702 1 1 Cover, Bumper, ACC, LH Cover, Bumper, ACC, RH 18 5435357-070 1 Panel, Bumper, Front, Black 19 7518383 2 Screw 20 7518382 2 Bolt 21 7556341 4 Washer, Flat 22 2632865-070 1 Asm., Bumper, Front, Black (Incl. Warning Decal) 23 1202838 1 Asm., Box, Lower, Front 24 5412352 3 Plug, Compartment 25 5812778 1 Seal, Radiator Cover 26 5435628 2 Cover, Strut 27 7555960 4 Washer, Flat 28 7517208 4 Screw 29 5521693 1 Seal 30 5521706 1 Seal, Lid/Bumper 31 5134576 2 Pin, Hinge, Front 32 2633157 1 Asm., Front Cover (Incl. 30 and Warning Decal) 33 7542122 8 Nut, Nylok 34 7518427 8 Screw 35 5247653-418 2 Channel, Lid, Front, Flat Black Wrinkle 7/04

A9 STORAGE BOX, REAR SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW E 2004 Polaris Sales Inc. 3 1 6 4 5 7 2 8 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5435605 1 Box, Storage, Rear, Upper 2 7081205 1 Latch 3 5435368 1 Cover 4 5521694 1 Seal 5 5810455 2 Pad 6 5435630 1 Box, Storage, Rear, Lower 7 5412352 1 Plug, Compartment 8 7661855 2 Rivet 7/04

A10 DECALS SPORTSMAN 800 EFI A05MH76AC 17 15 14 10 16 13 5 4 8 3 1 8 E 2004 Polaris Sales Inc. 12 7 2 9 11 6 9 3 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7172689 2 Decal, Reflector, Red 2 7173013 1 Urocal, 50th Anniversary 3 7172749 2 Decal, Warning Front and Rear Rack 4 7172559 1 Decal, Age Warning, 16 5 7079780 1 Decal, Warning, AWD Switch 6 7172895 2 Decal, Headlight Pod, “EFI” 7 7173295 7173296 1 1 Decal, Sportsman 800 EFI, Tank Side, LH Decal, Sportsman 800 EFI, Tank Side, RH 8 7172687 7172688 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 9 7172893 7172894 1 1 Decal, Rear Cab, “AWD”, LH Decal, Rear Cab, “AWD”, RH 10 7078465 1 Logo, Polaris Star 11 7171067 1 Decal, New Break Up, Front Cover 12 7079672 1 Decal, Auxiliary Foot Brake 13 7172564 1 Decal, Warning, Override, AWD 14 7172560 1 Decal, Warning, General, CPSC 15 7172561 1 Decal, Discretional Warning 16 7172748 1 Decal, Tire Pressure/Load 17 7172566 1 Decal, Passenger Warning 10/04

POLARIS SPORTSMAN 800 TWIN EFI ATV Parts Manual Catalog

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