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

Polaris factory service manual for the 2005 Sportsman 700 EFI (A05MH68AU) and Sportsman 800 EFI (A05MH76AU/AW). P/N 9919820, copyright 2004, covers maintenance, diagnosis, component identification, and unit repair.

PDF Search, Bookmarks, and Diagram Detail

Text search and wiring detail: The main text is searchable, with embedded bookmarks for chapters and service topics. Wiring-diagram labels are not searchable. Small labels on the main diagram and wire-termination table require zooming and rotation; the winch diagram has faint linework.

One printable PDF contains 310 pages, including the covers, index, notes pages, manufacturer comment form, and one introductory third-party notice page.

Engine, EFI, and Drivetrain Service

The following selected service topics are part of the manual’s coverage. Other material includes periodic maintenance charts and care of the 800 EFI’s ceramic-coated exhaust canisters.

• Engine repair: Engine removal and installation, cylinder-head and valve-train service, piston/rod/ring inspection, crankcase overhaul, and camshaft and balance-shaft timing.

• Cooling and lubrication: Cooling-system pressure testing, coolant bleeding, oil-pressure testing, and water/oil-pump disassembly, inspection, and reassembly.

• Bosch EFI: MSE 1.1 ECU operation, fuel delivery, injectors, CPS, T-BAP, TPS, coolant sensor, TPS initialization, and blink-code diagnosis.

• PVT and transmission: EBS drive and driven clutch repair, bushing service, belt inspection, clutch alignment and offset, and transmission teardown and reassembly.

• AWD and final drive: Front and rear axle/CV-joint service, prop-shaft and U-joint repair, front gearcase diagnosis, and front/rear gearcase overhaul.

• Chassis and brakes: Body and rack removal, steering and toe adjustment, A-arm and front-strut repair, brake bleeding, fluid changes, caliper overhaul, disc inspection, and brake troubleshooting.

• Electrical diagnosis: Instrument-cluster troubleshooting, ignition and charging tests, relay and fuel-sender checks, starter-motor repair, winch wiring, and the two-page main vehicle wiring diagram.

Polaris wrote this manual primarily for certified Polaris Master Service Dealer technicians in a properly equipped shop; it assumes mechanical knowledge, correct tool use, and established service practices.

Internal Engine Repair and Cooling

Step-by-step procedures cover valve-seat reconditioning, cylinder and piston inspection, hydraulic-lifter service, and lower-engine assembly. The engine chapter distinguishes components accessible in the frame from work requiring engine removal.

The oil-flow chart and engine exploded views accompany component-specific torque tables, tightening sequences, fluid-capacity data, clearances, and wear limits. Cooling coverage also addresses trapped air as a cause of overheating.

EFI Tests and Equipment Requirements

Fuel-delivery checks, sensor tests, and wiring checks give technicians a way to compare electrical and fuel-system causes of hard starting or erratic running before selecting a repair.

The 800 EFI uses quick-connect fittings at the fuel rail and filter. The manual shows the different 700 connections and specifies replacement of the pump/tank assembly when the non-serviceable pump or regulator is faulty.

Equipment references include PU-47063 Polaris EFI Diagnostic Software (dealer-only), the PU-43506 fuel-pressure test kit, and the PU-47082 TPS tester. Manual test procedures are provided for several components, but T-BAP testing is referred to the dealer-only software and its separate EFI Diagnostic Software Manual, which is not included.

Further tool lists cover engine, suspension, brake, and electrical work.

Clutch Calibration and AWD Repair

Separate clutch charts specify springs and shift weights by model and altitude, along with the appropriate drive belts and clutch hardware. The drive-clutch and EBS exploded views show assembly differences, while Sportsman 800 drive-clutch bushing work specifically requires PA-47336.

AWD diagnosis addresses the centralized Hilliard gearcase’s coil, armature plate, and roller cage. Front-drive axle and propshaft views support the related removal and assembly work.

Brake Circuits and Electrical Fault Tracing

The rear caliper uses separate hand- and foot-brake hydraulic circuits, each requiring separate bleeding. The hand master cylinder is non-serviceable and replaced as a unit.

The Charging System Testing Flow Chart connects charging checks with stator, regulator, battery, and wiring diagnosis. Starter coverage extends to brush inspection and armature testing.

This is a service publication, not a replacement parts catalog. Parts ordering requires the correct model-specific parts manual.

Service Cautions

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

Over-threading flywheel-puller bolts can damage the stator coils. The PVT clutch is a precisely balanced assembly; mixing used parts from another clutch can compromise that balance.

Selected Oil-Pressure and Electrical Test Data

Oil-pressure specifications are 35–39 psi at 5,500 rpm with the engine at operating temperature and Polaris 0W-40 synthetic oil.

For AWD diagnosis, front gearcase coil resistance is specified at 22.8–25.2 ohms. The coolant-temperature sensor table lists 2.5 kΩ ± 6% at 68°F (20°C).