2005 Polaris Sportsman 700/800 EFI ATV Factory Service Manual (P/N 9919820)

• Coverage and document identity: Covers the 2005 Polaris Sportsman 700 EFI (A05MH68AU, 683cc twin-cylinder engine) and Sportsman 800 EFI (A05MH76AU/AW, 760cc twin-cylinder engine). This is the original Polaris Service Manual P/N 9919820, copyright 2004, supplied as a 310-page PDF.
• Engine repair: Documents engine removal and installation, cylinder-head and valve-train service, piston/rod/ring inspection, crankcase disassembly and reassembly, cam and balance-shaft timing, oil-pressure testing, cooling-system testing, and coolant bleeding.
• Bosch EFI diagnosis: Covers the Bosch MSE 1.1 ECU, fuel-pump/tank assembly, regulator, filters, injectors, fuel rail, CPS, T-BAP, TPS, coolant sensor, TPS initialization, blink-code diagnostics, and manual fault isolation.
• PVT, transmission, and final-drive work: Includes EBS drive and driven clutch repair, bushing service, belt inspection, clutch alignment and offset, model- and altitude-specific clutch charts, AWD axle and CV-joint service, front and rear gearcase repair, and full transmission teardown and reassembly.
• Chassis and brake service: Details body and rack removal, steering and toe adjustment, A-arm and front-strut repair, hydraulic brake bleeding and fluid replacement, master-cylinder service, caliper overhaul, disc inspection, and brake troubleshooting.
• Workshop reference material: Provides component-specific torque data, fastener sequences, capacities, clearance and wear specifications, electrical test values, troubleshooting charts, exploded views, a charging-system test flowchart, winch wiring, and the two-page main vehicle wiring diagram.

Factory Workshop Coverage

This manual goes well beyond scheduled maintenance. Its procedures reach into internal engine repair, clutch and transmission overhaul, EFI diagnosis, AWD gearcase work, suspension service, hydraulic brakes, and starting/charging systems. Polaris designed it primarily for certified Polaris Master Service Dealer technicians working in a properly equipped shop; the text assumes sound mechanical theory, correct tool use, and established shop practices.

The 700 and 800 share the twin-cylinder platform, but the manual does not treat them as interchangeable. It supplies separate engine service data and clutch calibration charts, identifies the correct drive belts and clutch hardware, and calls out model-specific fuel-system construction. The 800 EFI uses quick-connect fittings at the fuel rail and filter, while the 700 arrangement is shown with conventional connections. The in-tank pump, regulator, and sender are serviced as an assembly; the pump itself is not a separately replaceable component.

EFI and Electrical Diagnosis

EFI coverage follows sensor inputs and ECU-controlled outputs through the complete system rather than stopping at component location. Diagnostic material includes fuel-delivery checks, injector and sensor tests, wiring-connection checks, blink-code retrieval, TPS testing and initialization, instrument-cluster diagnostics, ignition fault tracing, charging tests, relay checks, fuel-sender testing, and starter-motor repair.

The manual identifies PU-47063 Polaris EFI Diagnostic Software as dealer-only equipment while also supplying manual test procedures. It lists the PU-43506 fuel-pressure test kit and PU-47082 TPS tester, along with engine, clutch, suspension, brake, and electrical service tools. Sportsman 800 drive-clutch bushing work specifically calls for PA-47336, an important equipment requirement when planning that repair.

Diagrams, Specifications, and Repair Depth

Useful illustrations include the EFI system exploded view, engine oil-flow chart, 700/800 drive-clutch and EBS exploded views, AWD front-drive axle and propshaft views, the charging-system testing flowchart, and the winch and main Sportsman 700/800 EFI wiring diagrams. Related tables cover torque sequences, lubrication and fluid data, component clearances, wear limits, clutch spring and shift-weight selection, and electrical test specifications.

This is a service publication, not a replacement parts catalog. The exploded views support service and assembly identification, but the manual directs parts ordering to separate model-specific parts manuals.

Important Service Cautions

The EFI system remains pressurized with the engine stopped, so the manual requires pressure relief and strict fire-safety precautions before fuel-system repair. It also warns that disconnecting or reconnecting ECU and component connectors with the ignition on can send a damaging voltage spike through the ECU.

Over-threading the flywheel-puller bolts can damage the stator coils. The PVT clutch is a precisely balanced assembly, and used parts from another clutch must not be mixed into it during repair.