Polaris Sportsman 800 Efi 2005 Manuals

Manuals and User Guides for Polaris Sportsman 800 Efi 2005. We have 2 Polaris Sportsman 800 Efi 2005 manuals available for free PDF download: Service Manual, Owner's Manual

Polaris Sportsman 800 Efi 2005 Service Manual (309 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 123.53 MB

General Maintenance

5
- Table of Contents
  5
- Model Identification
  6
- Serial Number Location
  6
  - Sportsman 800 Efi
    7
  - Specifications
    8
- Publication Numbers
  10
- Paint Codes
  10
- Replacement Keys
  10
- Standard Torque Specifications
  
  11
  - Special Tools
    11
- Torque Table
  
  16
  - Conversion Table
    16
- Tap Drill Charts
  
  18
  - Glossary of Terms
    18
- Decimal Equivalent Chart
  
  18
Maintenance

19
- Periodic Maintenance Chart
  20
  - Maintenance and Lubrication
    21
- Component Locations
  24
- Special Tools
  26
- Front & Rear Gearcase Lubrication
  29
  - Rear Gearcase
    30
- Transmission Lubrication
  31
  - Throttle Cable
    32
  - Throttle Inspection
    32
- Compression Test
  33
  - Fuel Filter
    33
- Battery Maintenance
  34
  - Engine Mounts
    34
  - Spark Plug
    35
- Ignition Timing
  35
  - Liquid Cooling System
    36
  - Coolant Level
    37
  - Cooling System Hoses
    37
- Radiator Screen Removal
  38
- Air Box Sediment Tube Service
  39
- PVT Drying & PVT Drain Plug
  40
  - Breather Hose
    40
  - Engine Oil Level
    41
- Oil and Filter Change
  42
  - Camber and Caster
    43
  - Wheel Alignment
    44
  - Toe Alignment
    45
  - Exhaust Pipe
    45
  - Brake Pad Inspection
    46
  - Brake System Inspection
    46
  - Auxiliary Brake
    47
- Controls
  48
  - Front Suspension
    48
  - Rear Suspension
    48
    
    Tire Pressure
    49
    
    Wheel Installation
    49
    
    Wheel Removal
    49
    
    Tire Inspection
    50
- Warn® Winch Operation
  51
- Cleaning and Storage
  53
  - Cleaning the Atv
    53
- 800 EFI Exhaust Canister Maintenance
  54
  - Battery Storage
    54
Table of Contents

55
- Engine Exploded Views
  56
  - Top End
    59
  - Electrical Components
    61
- Exhaust System
  62
- Piston Identification
  63
- Special Tools
  63
- Torque Specifications
  64
- Engine Fastener Torque Patterns
  65
- Engine Service Data
  
  69
  - Cooling System Specifications
    69
  - Cooling System Test
    69
- Engine Removal/Installation
  
  71
  - Engine Installation Notes
    71
    
    Cylinder Hone Selection and Honing Procedure
    73
    
    Engine Lubrication
    73
    
    Honing to Deglaze
    73
    
    Oil Pressure Test
    73
- Cylinder Honing
  
  74
  - Oil Flow
    74
  - Rocker Arm/Pushrod Inspection
    75
    
    Cylinder Head Removal
    75
  - Cylinder Head Disassembly/Inspection
    76
  - Valve Inspection
    78
  - Combustion Chamber
    79
  - Valve Seat Reconditioning
    79
  - Cylinder Head Assembly
    81
    
    Cylinder Head Reassembly
    81
  - Valve Sealing Test
    82
  - Valve Train Exploded View
    82
  - Engine Head Reassembly
    83
  - Cylinder Removal
    85
  - Piston Removal
    85
  - Valve Lifter Removal/Inspection
    85
  - Cylinder Inspection
    86
    
    Piston/Rod Inspection
    88
    
    Piston Ring Installed Gap
    89
- Piston/Rod/Ring Service
  
  90
  - Starter Bendix Removal/Inspection
    90
  - Flywheel/Stator Installation
    91
  - Flywheel/Stator Removal/Inspection
    91
  - Engine Crankcase Disassembly/Inspection
    92
    
    Cam Gear Disassembly
    94
    
    Cam Gear Removal
    94
  - Camshaft Inspection
    101
  - Engine Crankcase Assembly
    101
  - Troubleshooting
    113
    
    Cooling System
    114
Engine Notes

117
- Special Tools
  
  118
- Service Notes
  
  119
- EFI System Exploded View
  
  120
  - Efi System Component Locations
    121
- Fuel Tank Exploded View
  
  123
- Electronic Fuel Injection System
  
  123
  - Operation Overview
    123
  - Initial Start/Priming Procedure
    123
- Electronic Control Unit
  
  124
  - Service
    124
  - Replacement
    124
- Fuel Pump/Tank Assembly
  
  125
  - Test
    125
  - Replacement
    126
- Fuel Pressure Regulator
  
  127
  - Test
    128
  - Replacement
    128
- Fuel Injectors
  
  128
  - Service
    129
  - Replacement
    129
- Fuel Filters
  
  128
  - Service
    128
- Crankshaft Position Sensor
  
  129
  - Test
    130
  - Replacement
    130
- Temperature / Barometric Air Pressure Sensor
  
  130
  - Replacement
    131
- Throttle Position Sensor
  
  131
  - Test
    131
  - Replacement
    133
- Engine Temperature Sensor
  
  133
- Diagnostics Using "Blink Codes
  
  134
- Troubleshooting
  
  135
Fuel System / Fuel Injection Notes

137
- Side Panel Removal
  139
- Footwell Removal/Install
  140
- Front Cover Removal
  140
- Front Storage Removal/Install
  141
- Rear Rack Removal/Install
  143
  - Front Storage Installation
    143
- Rear Storage Removal/Install
  145
- Radiator Screen Removal
  146
- Body Assembly Exploded View
  147
  - Body Rack Exploded View
    148
- Headlight Pod Exploded View
  149
- Handlebar Block Installation Procedure
  150
- A-Arm Replacement
  152
- Rear Suspension Assembly
  153
  - Strut Assembly
    154
- Front Strut Cartridge Replacement
  155
  - Ball Joint Replacement
    155
- Decal Replacement
  156
- Steering Post Assembly
  156
Clutch

157
- Drive Clutch Exploded View
  
  158
  - PVT Sealing and Ducting Components
    158
- Special Tools, Supplies & Torques
  
  160
- EBS System Exploded View
  
  160
  - PVT Operation Overview
    160
    
    Drive Clutch Operation
    160
    
    Driven Clutch Operation
    160
    
    Pvt Drying
    161
- PVT Maintenance/Inspection/Drying 6.5
  
  162
  - PVT Overheating/Diagnosis
    162
  - PVT Disassembly
    163
  - PVT Assembly/Inspection
    164
  - Drive Clutch Spring Specifications
    165
  - Shift Weights /Inspection
    166
  - Drive Clutch Disassembly/Inspection
    167
    
    Spider Removal
    168
    
    Drive Clutch Inspection
    169
    
    Moveable Sheave Bushing Inspection
    170
  - Drive Clutch Reassembly
    171
  - Drive Belt Removal/Inspection
    172
  - Drive Belt Installation
    173
  - Clutch Alignment/Offset
    174
    
    Clutch Offset
    174
    
    Bushing Service
    175
    
    Removal and Installation
    175
- Driven Clutch Exploded View
  
  184
- Driven Clutch Service
  
  184
  - Troubleshooting
    184
    
    Final Drive
    188
    
    Front Hub Assembly
    191
    
    Front Hub Disassembly
    191
    
    Awd Front Drive Axle Exploded View
    194
    
    Rear Hub Installation
    206
    
    Rear Hub Assembly
    207
    
    Rear Hub Disassembly
    207
    
    Driveshaft/CV Joint Handling Tips
    208
    
    Rear Drive Shaft Removal
    208
    
    Rear Drive Shaft Installation
    209
    
    Rear Drive Shaft Service
    210
    
    Rear Gearcase Installation
    215
Transmission

217
- Transmission Exploded View
  218
- Gear Shift Selector Removal
  220
- Torque Specifications/Lubrication
  220
- Transmission Removal
  220
- Transmission Installation
  221
- Transmission Disassembly
  222
- Transmission Reassembly
  227
Brakes

233
- 2005 Sportsman EFI Dimensions
  234
  - Specifications
    234
    
    Brake System Components
    235
    
    Front Caliper Exploded View
    236
    
    Rear Caliper Exploded View
    236
    
    Brake Noise Troubleshooting
    237
    
    Brake System Service Notes
    237
    
    Hydraulic Brake System Overview
    238
    
    Brake Bleeding / Fluid Change
    239
    
    Hydraulic Caliper Bleeding
    239
    
    Master Cylinder Installation
    241
    
    Master Cylinder Removal
    241
    
    Front Pad Removal
    242
    
    Front Pad Assembly
    244
    
    Brake Burnishing
    245
    
    Front Disc Inspection
    245
    
    Front Disc Removal/Replacement
    245
    
    Front Caliper Disassembly
    246
    
    Front Caliper Removal
    246
    
    Front Caliper Inspection
    247
    
    Front Caliper Reassembly
    247
    
    Front Caliper Installation
    248
    
    Rear Pad Installation
    250
    
    Rear Caliper Removal/Inspection
    251
    
    Rear Caliper Assembly
    252
    
    Rear Disc Inspection
    253
    
    Troubleshooting
    255
Brakes Notes

257
- Crankshaft Position Sensor Gap
  258
- Gear Position Switch Test
  258
- Instrument Cluster Overview
  259
  - Diagnostic Mode
    260
  - Efi Diagnostic Mode
    262
- Speedometer Removal/Installation
  264
- Fan Motor Tests
  270
  - Fan Motor Current Draw
    270
  - Coolant Temperature Sensor
    270
    
    Fan Control Circuit Bypass Test
    270
    
    Etc Operation Test
    271
- Flywheel Identification
  272
- Ignition System Operation
  274
- Ignition System Troubleshooting
  274
  - Alternator Output Test
    275
- Charging System Testing Flow Chart
  277
- Battery Identification
  278
  - Battery Activation
    278
  - Conventional Battery
    278
  - Conventional Battery Installation
    279
  - Conventional Battery Specific Gravity Test
    280
  - Load Test
    280
  - Charging Procedure
    281
  - Off Season Storage
    281
  - Battery Charging
    282
  - Battery Testing
    283
    
    Battery Load Test
    284
    
    Low Maintenance Battery Charging
    284
    
    Bulb Replacement
    285
    
    Headlamp Switch Test
    288
- Fuel Sender Test
  290
  - Brake Light Switch
    290
- Accessory Wire Connections
  291
- Starter System Troubleshooting
  293
  - Starter Motor Removal
    293
  - Voltage Drop Test
    293
  - Armature Testing
    295
  - Starter Drive
    297
  - Starter Assembly
    298
  - Starter System Testing Flow Chart
    299

Polaris Sportsman 800 Efi 2005 Owner's Manual (119 pages)

Polaris 2005 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 31.79 MB

Welcome
6
Vehicle Identification Numbers
7
Table of Contents
8
Safety
9
- Safety Decals and Locations
  10
- Safe Riding Gear
  13
- Operator Safety
  14
- Know Your Vehicle
  14
- Age Restrictions
  14
- Safety Training
  14
- Equipment Modifications
  18
Features and Controls
35
- Throttle Lever
  36
- Brake Lever
  37
- Light Switches
  37
- Master Cylinder
  38
- Parking Brake
  39
- Setting the Parking Brake
  39
- Auxiliary Brake
  40
- Fuel Tank
  40
- Fuel Filter
  40
- Belt Life
  41
- Engaging the Front Gearcase
  42
- All Wheel Drive System
  42
- Instrument Cluster
  43
- Rider Information Center
  44
- Diagnostic Mode
  46
- Special EFI Diagnostic Mode
  48
- Fuel Safety
  49
Operation
49
- Break-In Period
  50
- Starting the Engine
  52
- Cold Weather Operation
  52
- Hauling Cargo
  53
- Driving Safely
  55
- Driving Procedures
  55
- Making Turns
  56
- Driving on Slippery Surfaces
  57
- Traveling Uphill
  58
- Traveling Downhill
  60
- Turning Around on a Hill
  61
- Driving through Water
  62
- Driving over Obstacles
  63
- Driving in Reverse
  64
- Parking on an Incline
  65
- Noise Emission Control System
  66
- Exhaust Emission Control System
  66
- Crankcase Emission Control System
  66
Emission Control Systems
66
Maintenance and Lubrication
67
- Periodic Maintenance Chart
  68
- Lubrication Guide
  72
- Premium 4 Synthetic Lubricant
  73
- Oil Level
  74
- Oil and Filter Change
  75
- Transmission Oil
  76
- Oil Change
  76
- Front Gearcase Oil
  77
- Oil Check
  77
- Rear Gearcase Oil
  78
- Engine Cooling System
  79
- Radiator Coolant Level
  79
- Coolant Level
  80
- Cooling System Operation
  80
- Toe Alignment
  83
- Steering Assembly
  83
- Footwell Removal
  84
- Side Panel Removal
  84
- Wheel Removal
  85
- Wheel Installation
  86
- Wheel Nut Torque Specifications
  86
- Front Wheel Hub Tightening
  86
- Filter Systems
  87
- Air Filter Service
  87
- Headlight Lamp Replacement
  88
- High Beam Adjustment
  89
- Low Beam Adjustment
  89
- Headlight Housing Replacement
  90
- Spark Plugs
  92
- Vehicle Immersion
  93
- Spark Arrestor
  94
- Pvt System
  95
- Low Range
  95
- High Range
  95
- Pvt Drying
  96
- Battery Removal
  97
- Battery Installation
  97
- Battery Charging
  98
- Battery Storage
  98
- Cleaning and Storage
  100
- Fluid Levels
  101
- Battery Maintenance
  102
- Transporting the Atv
  103
- Rear Spring
  104
- Camber and Caster
  104
Adjustments
104
Throttle Cable Freeplay
105
Troubleshooting
106
- Engine Backfires
  108
- Engine Runs Irregularly, Stalls or Misfires
  108
- Engine Overheating
  109
Polaris Products
110
Specifications
111
Clutching Chart
112
Warranty
113
Engine Oil
115
Index
118

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Polaris Sportsman 800 Efi 2005 Manuals

Polaris Sportsman 800 Efi 2005 Service Manual (309 pages)

Table of Contents

General Maintenance

Standard Torque Specifications

Torque Table

Tap Drill Charts

Decimal Equivalent Chart

Maintenance

Table of Contents

Engine Service Data

Engine Removal/Installation

Cylinder Honing

Piston/Rod/Ring Service

Engine Notes

Special Tools

Service Notes

EFI System Exploded View

Fuel Tank Exploded View

Electronic Fuel Injection System

Electronic Control Unit

Fuel Pump/Tank Assembly

Fuel Pressure Regulator

Fuel Injectors

Fuel Filters

Crankshaft Position Sensor

Temperature / Barometric Air Pressure Sensor

Throttle Position Sensor

Engine Temperature Sensor

Diagnostics Using "Blink Codes

Troubleshooting

Fuel System / Fuel Injection Notes

Clutch

Drive Clutch Exploded View

Special Tools, Supplies & Torques

EBS System Exploded View

PVT Maintenance/Inspection/Drying 6.5

Driven Clutch Exploded View

Driven Clutch Service

Transmission

Brakes

Brakes Notes

Polaris Sportsman 800 Efi 2005 Owner's Manual (119 pages)

Table of Contents

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