Polaris Sportsman 700-800 (2005-07) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 700-800 (2005-07) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 700 800 (2005-07).

 
CONTENTS:

2005 SERVICE MANUAL

INTRODUCTION
TABLE OF CONTENTS
CHAPTER 1 GENERAL
- Model Identification
- Serial Number Location
- 2005 Sportsman Efi Dimensions
- Specifications - Sportsman Efi
- Publication Numbers
- Paint Codes
- Replacement Keys
- Standard Torque Specifications
- Special Tools
- Torque Table
- Conversion Table
- Tap Drill Charts
- Decimal Equivalent Chart
- Glossary Of Terms
CHAPTER 2-MAINTENANCE
- Periodic Maintenance Chart
- Component Locations
- Lubricant And Maintenance Product Numbers
- Special Tools
- Lubrication Charts
- Front & Rear Gearcase Lubrication
- Transmission Lubrication
- Throttle Cable Adjustment
- Transmission Linkage Inspection
- Fuel System
- Compression Test
- Battery Maintenance
- Ignition
- Coolant System Maintenance
- Radiator Screen Removal
- Air Filter Service
- Air Box Sediment Tube Service
- Breather Filter
- Pvt Drying & Pvt Drain Plug
- Oil Change/Filter
- Steering And Toe Alignment
- Exhaust System Maintenance
- Brake System Service
- Suspension Service
- Controls
- Wheel/Tire --Removal/Installation/Inspection
- Warn® Winch Operation
- Cleaning And Storage
- 800 Efi Exhaust Canister Maintenance
CHAPTER 3-ENGINE
- Engine Exploded Views
- Exhaust System View / Notes
- Special Tools
- Piston Identification
- Torque Specifications
- Engine Fastener Torque Patterns
- Engine Service Data
- Cooling System Specifications
- Cooling System Test
- Engine Removal/Installation
- Engine Installation Notes
- Cylinder Honing
- Oil Flow
- Rocker Arm/Pushrod Inspection
- Cylinder Head Disassembly/Inspection
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Valve Train Exploded View
- Engine Head Reassembly
- Cylinder Removal
- Valve Lifter Removal/Inspection
- Piston Removal
- Cylinder Inspection
- Piston/Rod/Ring Service
- Starter Bendix Removal/Inspection
- Flywheel/Stator Removal/Inspection
- Flywheel/Stator Installation
- Engine Crankcase Disassembly/Inspection
- Camshaft Inspection
- Engine Crankcase Assembly
- Troubleshooting
- 4--Stroke Coolant System Bleeding Procedure
CHAPTER 4-FUEL INJECTION
- 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 Filters
- Fuel Injectors
- Crankshaft Position Sensor
- Temperature / Barometric Air Pressure Sensor
- Throttle Position Sensor
- Engine Temperature Sensor
- Diagnostics Using “Blink Codes”
- Troubleshooting
CHAPTER 5-BODY AND STEERING
- Torque Specifications And Special Tools
- Cover/Panel Removal
- Side Panel Removal
- Front Cover Removal
- Footwell Removal/Install
- Front Storage Removal/Install
- Rear Rack Removal/Install
- Front Cab Removal/Install
- Rear Cab Removal/Install
- Rear Storage Removal/Install
- Radiator Screen Removal
- Body Assembly, Exploded View
- Headlight Pod Exploded View
- Handlebar Block Installation Procedure
- Steering Assembly, Exploded View
- A-Arm Replacement
- Rear Suspension Assembly
- Strut Assembly Exploded View
- Front Strut Cartridge Replacement
- Front Strut Ball Joint Replacement
- Steering Post Assembly
- Decal Replacement
CHAPTER 6-CLUTCHING
- Drive Clutch Exploded View
- Pvt Sealing And Ducting Components
- Ebs System Exploded View
- Special Tools, Supplies & Torques
- Pvt Operation Overview
- Pvt Maintenance/Inspection/Drying
- Pvt Overheating/Diagnosis
- Pvt Disassembly
- Pvt Assembly/Inspection
- Drive Clutch Spring Specifications
- Shift Weights /Inspection
- 700 Drive Clutch Disassembly/Inspection
- 700 Drive Clutch Reassembly
- Drive Belt Removal/Inspection
- Drive Belt Installation
- Clutch Alignment/Offset
- Drive Clutch Bushing Service
- Driven Clutch Service
- Driven Clutch Exploded View
- Troubleshooting
CHAPTER 7-FINAL DRIVE
- Final Drive Torque Specifications
- Awd Front Axle Remove/Install
- Awd Front Cv Joint Boot Replace.
- Awd Front Drive Axle Exploded View
- Front Hub Disass./Assemble
- Awd Front Prop Shaft Removal
- U-Joint Disassemble/Assemble
- Drive Axle / Propshaft Exploded View
- Awd Front Gearcase Operation
- Awd Front Gearcase Service
- Rear Hub Remove/Install
- Rear Hub Disassembly/Assembly
- Rear Drive Shaft Removal
- Driveshaft / Cv Joint Tips
- Rear Driveshaft Installation
- Rear Driveshaft Service
- Rear Gearcase Service
CHAPTER 8-TRANSMISSION
- Transmission, Exploded View
- Torque Specifications/Lubrication
- Gear Shift Selector Removal
- Transmission Removal
- Transmission Installation
- Transmission Disassembly
- Transmission Reassembly
CHAPTER 9-BRAKES
- Special Tools/Specifications/Torques
- Brake System Components
- Rear Caliper Exploded View
- Front Caliper Exploded View
- Rear Auxiliary Master Cylinder Exploded View
- Brake System Service Notes
- Brake Noise Troubleshooting
- Hydraulic Brake System Overview
- Hydraulic Caliper Bleeding
- Brake Bleeding / Fluid Change
- Master Cylinder Removal
- Master Cylinder Installation
- Front Pad Removal
- Front Pad Assembly
- Brake Burnishing
- Front Disc Inspection
- Front Disc Removal/Replacement
- Front Caliper Removal
- Front Caliper Disassembly
- Front Caliper Inspection
- Front Caliper Reassembly
- Front Caliper Installation
- Rear Pad Removal
- Rear Pad Installation
- Rear Caliper Removal/Inspection
- Rear Caliper Reassembly
- Rear Disc Inspection
- Rear (Auxiliary) Brake Remove/Install
- Troubleshooting
CHAPTER 10-ELECTRICAL
- Crankshaft Position Sensor Gap
- Gear Position Switch Test
- Instrument Cluster Overview
- Speedometer Removal/Installation
- Speedometer Operation Troubleshooting
- Coolant Sensor Tests
- Fan Motor Tests
- Fan Control Switch Tests
- Electronic Throttle Circuit System Operation
- Flywheel Identification
- Ignition System Operation
- Ignition Components
- Ignition System Troubleshooting
- Charging System Testing
- Fan / Ecu Relays
- Charging System Testing Flow Chart
- Battery Identification
- Conventional Battery Activation/Service
- Low Maint. Battery Activation/Service
- Head Light/ Lamp / Switch Service
- Work / Brake Light Lamp /Switch Service
- Fuel Sender Test
- Accessory Wire Connections
- Winch Wiring Diagram
- Starter System Troubleshooting
- Starter Motor Service
WIRING DIAGRAMS


2007 SERVICE MANUAL


FOREWORD
- Understanding Manual Safety Labels And Directions
- Trademarks
CHAPTER INDEX
CH 1 - GENERAL INFORMATION
- Model Information
- Model Number/Vin Identification
- 2007 Sportsman 700 Efi
- Specifications, Sportsman 700 Efi
- 2007 Sportsman 800 Efi
- Specifications, Sportsman 800 Efi
- 2007 Sportsman X2 800 Efi
- Specifications, Sportsman 800 X2 Efi
- Misc. Tables
- Misc. Numbers/Charts
CH 2 - MAINTENANCE
- Maintenance
- Maintenance Chart, Periodic
- Lubrication / Fluids
- Vehicle Inspection
- Specification, Wheel Toe-Out
CH 3 - ENGINE
- Specifications
- General Engine Service
- Specifications, Engine Oil Pressure
- Engine Disassembly And Inspection
- Specification, Cylinder Head Warp
- Specification, Valve Spring Free Length
- Specification, Valve Stem Diameter
- Specification, Valve Stem Guide I.D.
- Specification, Valve Seat Contact Width
- Specification, Cylinder Warp Limit
- Specification, Cylinder Taper Limit
- Engine Flywheel Removal
- Engine Starter Removal
- Engine Gear(s) Removal
- Specification, Timing Gear Alignment
- Timing Gear Mark Alignment
- Cam Gear, Removal
- Cam Gear, Reassembly
- Special Tool, Cam Gear Installation Kit
- Balance Shaft Gear, Removal
- Crankshaft Gear, Removal
- Engine Crankshaft Gear Removal
- Oil Pump, Removal
- Engine Oil Pump Removal
- Oil Pump, Disassembly
- Specification, Oil Pump Rotor Clearance
- Oil Pump, Reassembly
- Engine Balance Shaft Removal
- Specification, Cam Lobe Height
- Specifications, Cam Shaft
- Engine Reassembly
- Specifications, Oil Baffle Bolt Torque
- Specifications, Oil Pick-up Bolt Torque
- Engine Camshaft Installation
- Engine Crankshaft Installation
- Specifications, Crankcase Fastener Torque
- Engine Cylinder Installation
- Engine Piston Installation
- Specification, Cam Thrust Plate Fastener Torque
- Engine Oil Pump Installation
- Specification, Oil Pump Bolt Torque
- Engine Gears, Installation
- Specification, Balance Shaft Gear Bolt Torque
- Specification, Camshaft Gear Bolt Torque
- Gear / Stator Housing Seal Replacement
- Engine Stator Gear Cover Seal(s) Installation
- Engine Stator Installation
- Engine Oil Priming
- Troubleshooting
- 800 Efi Exhaust System (Deluxe)
CH 4 - FUEL INJECTION
- General Information
- Electronic Fuel Injection
- Electronic Control Unit (Ecu)
- Fuel Pump
- Fuel Pressure Regulator
- Fuel Filters
- Fuel Injectors
- Crankshaft Position Sensor (Cps)
- Temperature / Barometric Air Pressure Sensor (T-Bap)
- Throttle Position Sensor (Tps)
- Engine Temperature Sensor
- Troubleshooting
CH 5 - BODY/STEERING/SUSPENSION
- General Information
- Body
- Steering
- Steering Post Removal
- Suspension
- X2 Cargo Box
- X2 Seat Assembly
CH 6 - CLUTCH SYSTEM
- Special Tools And Specifications
- Pvt Exploded Views
- Pvt System
- Specification, PVT Drive Belt Width
- Specification, PVT Center-to-Center Distance
- Ebs Drive Clutch Service
- Ebs Drive Clutch Service
- Ebs Driven Clutch Service
- Ebs Driven Clutch Service
- Standard Drive Clutch
- Drive Clutch, Standard Service
- Standard Driven Clutch
- Driven Clutch, Standard Service
- Pvt Troubleshooting
- Clutch, Troubleshooting
CH 7 - FINAL DRIVE
- Specifications
- Front Drive Axle
- Front Drive Shaft (Cv) Boot
- Front Hub
- Prop Shaft - Front Or Rear
- U-Joint
- U-Joint, Disassembly And Assembly
- Drive Axle Exploded Views
- Front Gearcase - Centralized Hilliard (Standard Models)
- Front Gearcase, Operation
- Front Gearcase Coil Resistance
- Front Gearcase - Back Lash Pad Adjustment
- Front Gearcase - Active Descent Control (Deluxe Models)
- Front Gearcase Coil Resistance
- Rear Hub
- Rear Drive (Cv) Shaft
- Rear Gearcase
- Sportsman 8.3-8.18
- Sportsman X2 8.19-8.38
CH 8 - TRANSMISSION / SPORTSMAN
- Transmission Exploded View
- Specificiatons
- Transmission Service
CH 8 - TRANSMISSION / X2
- Transmission
- X2 Transmission Exploded View
- Transmission, Exploded View
- X2 Mounting Exploded View
- Transmission Mounts, Exploded View
- Torque Specifications
- Special Tools
- Transmission, Special Tools
- Lubrication
- Gear Selector Removal
- Transmission Removal
- Transmission, Removal
- Transmission Installation
- Transmission, Install
- Troubleshooting Checklist
- Transmission Disassembly
- Transmission, Disassembly
- Transmission assembly
- Transmission, Reassembly
- Transmission front output shaft backlash procedure
- Transmission, Output Shaft Backlash Procedure
- Specification, Transmission Silent Chain Length
CH 9 - BRAKES
- Specifications
- Brake System Exploded Views
- Brake System Exploded Views
- Brake Caliper Exploded Views
- Brake Caliper Exploded View
- Hydraulic Brake System
- Hydraulic Brake System Operation Overview
- Front Master Cylinder
- Brake, Master Cylinder Removal
- Front Brakes
- Brake Pad, Removal And Installation
- Front Brake Disc
- Brake Disc, Front
- Front Caliper
- Brake Caliper, Front
- Rear Brake Pad
- Brake Pad, Rear
- Specification, Brake Pad Thickness
- X2 Rear Caliper
- Brake Caliper Removal, Rear
- Sportsman Rear Caliper
- Rear Brake Disc
- Brake Disc, Inspection
- Specification, Brake Disc Thickness
- Specification, Brake Disc Service Limit
- Rear Master Cylinder
- Brake, Rear Auxiliary Master Cylinder
- Troubleshooting
- Brakes, Troubleshooting
CH 10 - ELECTRICAL
- Instrument Cluster
- Instrument Cluster (Speedometer) Overview
- Speedometer Troubleshooting
- Active Descent Control (Adc) Coil
- Active Descent Control (Adc) Coil
- All Wheel Drive (Awd) Coil
- All Wheel Drive (Awd) Coil
- Cooling System Components
- Gear Position Indicator Switch
- Electronic Throttle Control (Etc) Switch
- Ignition System
- Charging System
- Relays
- Fuses/Circuit Breaker
- Lighting
- Lower Headlamp Housing Removal
- Fuel Sender
- X2 Differential System
- Specification, Differential Solenoid Torque
- X2 Speed Sensor
- Specification, Differential Solenoid Torque
- Accessory Power
- Starter System
- Starter System Testing Flow Chart
- Basic Winch Wiring- Pre-Wired Models
- Battery
CH 11 - INTERNATIONAL
- 800 Efi International Brake System
- Brake System Overview, International
- 800 Efi International Steering Post And Lock Assembly
- 800 Efi International Electrical
INDEX
WIRE DIAGRAMS