2005 Sportsman 800 Efi - A05mh76ac, Au, Aw - PM

PARTS MANUAL PN 9917721 and MICROFICHE PN 9917722 10/04
SPORTSMAN 800 EFI

Model #A05MH76AC
SPORTSMAN 800 EFI
Model #A05MH76AU
SPORTSMAN 800 EFI
Model #A05MH76AW
E 2004 Polaris Sales Inc.
TABLE OF CONTENTS
SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW
Parts Manual
A--ARM . . . . . . . . . . . . . . . . . . . . . . . . . C7
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . B3
BRAKE LINES, FRONT . . . . . . . . . . . . . B7

BRAKE, FRONT . . . . . . . . . . . . . . . . . . . B6
BUMPER MOUNTING . . . . . . . . . . . . . . . A7-8
CAB, FRONT . . . . . . . . . . . . . . . . . . . . .
CAB, REAR . . . . . . . . . . . . . . . . . . . . . .
CALIPER, REAR . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . .
CONTROLS . . . . . . . . . . . . . . . . . . . . . .
CONTROLS -- THROTTLE ASM./CABLE .
COOLING SYSTEM . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . .
DECALS . . . . . . . . . . . . . . . . . . . . . . . .
DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT, FRONT . . . . . . . . . . . . . .
DRIVE SHAFT, REAR . . . . . . . . . . . . . . .
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . .
A5
A3-4
B8
C12
B5
B10
A13-14
D11-12
D11-12
D14
A10-11
E3
C10
B11
B12
C11
FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . B9
FUEL INJECTOR . . . . . . . . . . . . . . . . . . E5
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . B4
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . E2
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . E6
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . D13
MASTER CYLINDER, REAR . . . . . . . . . . B9
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . E3
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . E4
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . D14
PROP SHAFT, FRONT . . . . . . . . . . . . . . B13
PROP SHAFT, REAR . . . . . . . . . . . . . . . B14
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . D3--4
ENGINE MOUNTING . . . . . . . . . . . . . . . . B1-2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . A12
GEAR SELECTOR . . . . . . . . . . . . . . . . .
GEARCASE . . . . . . . . . . . . . . . . . . . . . .
GEARCASE MOUNTING, REAR . . . . . . .
GEARCASE, REAR . . . . . . . . . . . . . . . . .
HEADLIGHT POD . . . . . . . . . . . . . . . . . . C1--2

HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . C6
HOUSING, FRONT . . . . . . . . . . . . . . . . . D6
C9
D7-8
D10
D9
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . C1-2
RACK MOUNTING, REAR . . . . . . . . . . . A6
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . .
STORAGE BOX, REAR . . . . . . . . . . . . .
STORAGE, FRONT . . . . . . . . . . . . . . . . .
STORAGE, FRONT . . . . . . . . . . . . . . . .
STRUT MOUNTING . . . . . . . . . . . . . . . .
STRUT, FRONT . . . . . . . . . . . . . . . . . . .
SUSPENSION, REAR . . . . . . . . . . . . . . .
TAILLAMPS . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . .
THROTTLE BODY MOUNTING . . . . . . . .
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION MOUNTING . . . . . . . . .
WATER PUMP . . . . . . . . . . . . . . . . . . . .
WHEEL, FRONT . . . . . . . . . . . . . . . . . . .
WHEEL, REAR . . . . . . . . . . . . . . . . . . . .
WORKLAMPS . . . . . . . . . . . . . . . . . . . .
A3-4
E7
C8
A9
A8
A7
C7
C3
D1-2
C6
D13
E1
E8
D5
E4
C4-5
C13-14
C6
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
CAB, REAR and SEAT

1
3
4
2
11
30
27
28
8
9
26
25
29
24
12
10
23
11
22
11
12
21
13
18
19
14
15
16
19
17
A3
20
CAB, REAR and SEAT

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
Qty. Description
7512095
7555798
7512026
7556034
5246076
7511930
7555792
7541925
5435664-455
2
2
3
3
1
2
2
2
1
5435363-177
5436108-177
5435363-070
5436108-070
10 7170509
11 7661855
12 5435354-070
5435355-070
1
14
1
1
Screw
Washer
Screw
Washer
Retainer, Seat Latch
Screw
Washer
Nut, Nylok
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)
Decal, Hitch
Rivet
Footwell, Black, LH
Footwell, Black, RH
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
7517230
7542122
5812703
5812702
5812701
1014951-067
7515399
5245767-067
7542153
7512283
5244751-067
7621403
5211033
7041370
2683661-070
2683433-070
2683434-070
28 1040387
29 5412623
30 7172921
Qty. Description
8
8
1
1
1
1
4
1
6
6
1
2
2
1
1
1
1
1
2
1
Screw
Nut, Nylok
Foil, Rear Cab, Front, Top
Foil, Rear, Cab, Front, Bottom
Foil, Cab, Rear
Frame, Main, Black
Screw
Bracket, Bumper, Lower, Black
Nut, Nylok, Flange
Screw
Brace, Support, Frame, Front, Black, LH
Rivet
Bracket, Lever Retainer
Spring, Latch
Asm., Seat, Black (AC)
Asm., Seat, Black (AW)(AU)
Covering, Seat, Black
Latch, Seat
Grommet, Rubber Mount
Decal, Filter Cleaning
10/04
A4
CAB, FRONT
1
5
11
2
4
10
12
11
5
6
7
9
7
8
Ref. Part No.
1 5435668-455
5435352-177
5435352-070
2 2632975-455
2632864-177
2632864-070
3 7670057
4 7517219
5 5435919-455
2633048-455
5435506-293
2632936-293
5435559-473
2632936-473
Qty. Description
1
1
1
1
1
1
2
2
1
1
1
1
1
1
Cover, Front, NBU Camo (AC)

Cover, Front, Black Metallic (AU)
Cover, Front, Black (AW)
Asm., Cab, Front, NBU Camo (AC)
Asm., Cab, Front, Black Metallic (AU)
Asm., Cab, Front, Black (AW)
Nut, Speed
Screw
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)
Ref. Part No.
6
7
8
9
10
11
12
5812615
7517386
5248100
5246872
7661855
7512026
7556034
Qty. Description
1
4
1
1
2
8
4
Foil, RH
Screw
Guard, Splash, RH
Guard, Splash, LH
Rivet
Screw
Washer
10/04
A5
RACK MOUNTING, REAR


1
19
2
4
18
5
6
12
7
8
15
9
10
11
12
17
13
14
16
15
Ref. Part No.
1
2
3
4
5
6
7
7517230
7517983
5248469-418
7518418
1014768-418
7517208
2632867-070
8 7518213
9 5435959
10 7555843
Qty. Description
4
2
1
2
1
6
1
Screw
Screw
Channel, Rear Rack, Flat Black Wrinkle
Screw
Extender, Rear Rack
Screw
Asm., Rack, Rear, Flat Black Wrinkle
(Incl. Warning Decal and Reflectors)
2 Screw
2 Spacer
2 Washer, Flat
Ref. Part No.
11 7542324
12 5248471-418
13
14
15
16
5334092
1014668-067
7518341
-------
17 7542343
18 7542153
19 7518424
Qty. Description
2 Nut, Nylok
2 Channel, Rear Rack, Front, Flat Black
Wrinkle
2 Spacer
1 Support, Rear Rack, Black
4 Bolt, Flange
1 Bracket, Silencer, Frame (See Exhaust System Pg. A12, Ref. 6)
4 Nut, Flange
4 Nut, Nylok, Flange
2 Screw
8/04
A6
STORAGE, FRONT and BUMPER MOUNTING

34
2
33
1
32
35
31
30
29
31
6
2
1
28
7
26
25
9
27
24
8
9
10
23
22
10
21
12
13
14
11
20
19
16
18
15
17
A7
STORAGE, FRONT and BUMPER MOUNTING

Ref. Part No.
1 7515399
2 1014591-067
1014592-067
3 7518341
4 7542343
5 1014635-067
6 5435629
7 7081241
7081242
8 7512076
9 5334257
10 5434314
5434315
11 7661855
12 5412504
13 5435046
14 5247507-067
15 7518046
16 7172687
7172688
17 5435701
5435702
Qty. Description
6
1
1
2
2
1
1
1
1
4
2
1
1
6
4
1
1
4
1
1
1
1
Screw
Support, Rack, Black, LH
Support, Rack, Black, RH
Bolt, Flange
Nut, Flange
Guard, Brush, Black
Cover, Radiator
Latch, LH
Latch, RH
Screw
Latch, Wire
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
Rivet
Grommet, Rubber Mount
Cover, Radiator
Grill, Brush Guard, Black
Screw
Decal, Amber Reflector, LH
Decal, Amber Reflector, RH
Cover, Bumper, ACC, LH
Cover, Bumper, ACC, RH
Ref. Part No.
Qty. Description
18
19
20
21
22
5435357-070
7518383
7518382
7556341
2632865-070
1
2
2
4
1
23
24
25
26
27
28
29
30
31
32
1202838
5412352
5812778
5435628
7555960
7517208
5521693
5521706
5134576
2633157
1
3
1
2
4
4
1
1
2
1
33 7542122
34 7518427
35 5247653-418
8
8
2
Panel, Bumper, Front, Black

Screw
Bolt
Washer, Flat
Asm., Bumper, Front, Black
(Incl. Warning Decal)
Asm., Box, Lower, Front
Plug, Compartment
Seal, Radiator Cover
Cover, Strut
Washer, Flat
Screw
Seal
Seal, Lid/Bumper
Pin, Hinge, Front
Asm., Front Cover
(Incl. 30 and Warning Decal)
Nut, Nylok
Screw
Channel, Lid, Front, Flat Black Wrinkle
7/04
A8
STORAGE BOX, REAR

5
6
Ref. Part No.
1
2
3
4
5435605
7081205
5435368
5521694
Qty. Description
1
1
1
1
Ref. Part No.
Box, Storage, Rear, Upper

Latch
Cover
Seal
5
6
7
8
5810455
5435630
5412352
7661855
Qty. Description
2
1
1
2
Pad
Box, Storage, Rear, Lower
Plug, Compartment
Rivet
7/04
A9
DECALS
SPORTSMAN 800 EFI A05MH76AC
6
7
3

9
8
12
13
14
15
11
10
16
17
8
Ref. Part No.
1
2
3
4
5
6
7
7172689
7173013
7172749
7172559
7079780
7172895
7173295
7173296
8 7172687
7172688
Qty. Description
2
1
2
1
1
2
1
1
1
1
Decal, Reflector, Red

Urocal, 50th Anniversary
Decal, Warning Front and Rear Rack
Decal, Age Warning, 16
Decal, Warning, AWD Switch
Decal, Headlight Pod, EFI
Decal, Sportsman 800 EFI, Tank Side, LH
Decal, Sportsman 800 EFI, Tank Side, RH
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Ref. Part No.
9 7172893
7172894
10 7078465
11 7171067
12 7079672
13 7172564
14 7172560
15 7172561
16 7172748
17 7172566
Qty. Description
1
1
1
1
1
1
1
1
1
1
Decal, Rear Cab, AWD, LH

Decal, Rear Cab, AWD, RH
Logo, Polaris Star
Decal, New Break Up, Front Cover
Decal, Auxiliary Foot Brake
Decal, Warning, Override, AWD
Decal, Warning, General, CPSC
Decal, Discretional Warning
Decal, Tire Pressure/Load
Decal, Passenger Warning
10/04
A10
DECALS
SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW
3
4
9
3
1
10
12
14
13
15
11
17
16
Ref. Part No.
1
2
3
4
5
6
7
8
9
7172689
7173013
7172749
7172707
7172708
7172559
7172704
7172710
7079780
7172709
7172717
7172718
Qty. Description
2
1
2
1
1
1
1
1
1
2
1
1
Decal, Reflector, Red

Urocal, 50th Anniversary
Decal, Warning, Rack, Front/Rear
Decal, Rear Cab, AWD, LH
Decal, Rear Cab, AWD, RH
Decal, Age Warning, 16
Decal, SPORTSMAN, LH
Decal, SPORTSMAN, RH
Decal, Switch Warning, AWD
Decal, Headlight Pod, EFI
Decal, Tank Side, 800 TWIN, LH
Decal, Tank Side, 800 TWIN, RH
Ref. Part No.
10 7172687
7172688
11 7078465
12 7079672
13 7172564
14 7172560
15 7172561
16 7172748
17 7172566
Qty. Description
1
1
1
1
1
1
1
1
1
Decal, Reflector, Amber, LH

Decal, Reflector, Amber, RH
Logo, Polaris Star
Decal, Auxiliary Foot Brake
Decal, Override Warning, AWD
Decal, Warning, General, CPSC
Decal, Warning, Discrectionary
Decal, Tire Pressure/Load
Decal, Passenger Warning
10/04
A11
EXHAUST SYSTEM
1
2
3
4
1
2
3
28
26
27
7
8
25
23
24
9
10
11
22
16
12
15
15
16
21
13
14
15
20
16
17
19
18
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7542324
7555716
5010192
5410436
7555863
5241663
5412508
7515316
1261449
7556230
7512666
3610047
7041789
1261445-029
Qty. Description
2
2
2
2
2
1
2
2
1
1
1
1
2
1
Nut, Nylok
Washer
Bushing
Washer, Rubber
Bushing
Bracket, Silencer, Frame
Dampener, Vibration
Bolt
Exhaust, Silencer, RH
Washer, Clean Out
Bolt
Seal, Exhaust Socket
Spring
Exhaust, Pipe, Dual, Black
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
7515197
7555935
5248702
7547076
7556353
5811511
5248703
5244014
5246375
7081244
1261448
5412727
5248723
7042266
Qty. Description
6
6
1
4
4
1
1
1
1
1
1
2
1
1
Screw
Washer
Shield, Heat, Dual
Nut
Washer
Gasket
Shield, Heat, Exhaust, Top
Shield, Heat
Seal, Exhaust
Clamp, Exhaust
Exhaust, Silencer, LH
Grommet, Silencer, Mount
Bracket, Silencer, Mount
Spring
10/04
A12
COOLING SYSTEM
11
12
14
15
13
16
5
17
1
10
2
18
19
8
7
20
21
23
24
22
38
7
27
26
9
7
25
28
37
24
29
35
11
34
33
32
30
36
31
A13
COOLING SYSTEM
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
7517975
7547197
2410366
7547220
7080003
8450040
7081047
5435196
7512084
1240044
7081174
5521597
5412391
8360012-17
5430743
5810279
5433774
5431673
7052065
Qty. Description
4
4
1
4
2
1
6
1
5
1
2
2
1
1
1
1
1
1
1
Bolt
U-Clip
Asm., Fan
Screw w/Washer
Clamp, Hose
Line
Clamp
Filler, Neck
Screw
Cap, Pressure
Clamp, Hose
Guard, Hose
Hose, Engine, Upper
Trim, Edge
Cap, Overflow
Gasket
Plug, Cap
Tank, Surge
Fitting, 90 Degree
Ref. Part No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
8450003-1525
7080307
5246656
5412311
5521644
7052342
5412392
5411975
7515179
1240190
7517386
5245773-067
5410584
7052296
7080138
5412585
7080492
7042089
5434853
Qty. Description
1
1
1
1
2
1
1
2
2
1
2
1
2
1
1
1
1
1
1
Line, Fuel
Clamp, Hose
Bracket, Radiator Mount, Upper
Hose, Filler Neck
Guard, Hose
T-Connector
Hose, Lower Radiator
Asm., Grommet and Insert
Screw
Radiator
Screw
Bracket, Radiator, Lower, Black
Bushing, Mount, Lower Radiator
Valve, Drain
Cable Tie
Hose, Engine, Lower
Cable Tie
Retainer, Hose
Shroud, Fan
8/04
A14
ENGINE MOUNTING
18
19
17
16
20
1
15
14
8
3
5
2
5
13
12
B1
10
11
ENGINE MOUNTING
Ref. Part No.
1 2202915
2
3
4
5
6
7
8
7547263
5244771-067
7555823
3110044
5245043
7518364
7555815
Qty. Description
1 Kit, Short Block, 800 EFI NOTE: The

Short Block assembly contains a
crankcase assembly, cylinder & cylinder head assembly and a piston &
crankshaft assembly. Prior authorization is required for warranty consideration.
2 Nut, Nylok
1 Mount, Engine, Lower, Front, Black
AR Washer
2 Mount, Rubber, Top
1 Bracket, Torque Stop
2 Bolt
2 Washer, Flat
Ref. Part No.
9 3021119
10 7080451
11 5411944
5412634
12 7516734
13 5248701
14 7516734
15 7052038
16 8350018-06
17 3131514
18 1202578
19 3131515
20 7080236
Qty. Description
2
1
1
1
2
1
2
1
1
1
1
5
2
Mount, Rubber, Rear

Clamp, Hose
Boot, Intake (If built before 11/15/04)
Boot, Intake (If built after 11/15/04)
Screw
Bracket, Mount, RH
Screw
Valve, Check
Tubing
Guide, Throttle Cable
Asm., Cover and O-Ring
Screw
Clamp, Hose
11/04
B2
AIR BOX
2
3
31
30
10
29
11
28
27
19
12
18
13
17
26
25
24
23
22
21 20
16
15
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
5811633
7080595
7080413
5433847
5432868
7517317
5812773
5435932
5411422
5811482
5434044
7080451
-------
14 7080694
15 5412615
Qty. Description
1
1
1
1
1
4
1
1
1
1
1
2
1
Filter, Preclean Sleeve

Filter, Air
Clamp, Narrow Band
Sleeve, Carburetor, Inner
Cover, Air Box
Screw
Seal, Foam, Large, Intake
Duct, Air Inlet, Large
Gasket, Intake
Seal, Cover
Duct, Clutch Air Inlet
Clamp, Hose
Boot, Clutch Intake (See Engine
Mounting Pg. B2, Ref. 11)
1 Clamp, Hose, Spring
1 Hose, Breather
Ref. Part No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
8450108-34
7080511
7080699
5433678
7080534
5433396
5242044
5432377
8450059-150
7080650
5811650
7555859
7515179
5412518
2410422
7517658
Qty. Description
AR
1
1
1
1
1
6
1
AR
1
1
2
2
1
1
1
Sheath, Reflective Sleeve

Clamp, Narrow Band
Clamp, Hose
Box, Air
Clamp, Hose
Cap, End
Clip
Plug, Trap
Line, Fuel
Clamp, Hose
Foil
Washer, Flat
Screw
Boot, Throttle Body
Sensor
Screw
10/04
B3
FUEL TANK
9
8
10

7
6
1
2
3
4
15
12
13
14
11
Ref. Part No.
1 7517685
2 5247184
5247185
3 5812004
4 5812005
5 2520437
6 5812265
7 5431053
Qty. Description
2
1
1
1
1
1
1
1
Screw
Bracket, Fuel Cover Mount, LH
Bracket, Fuel Cover Mount, RH
Foil
Foil
Tank, Fuel
Seal, Foam
Vent, Tank
Ref. Part No.
8
9
10
11
12
13
14
15
8360009-600
5433687
5812123
2520443
5436013
7512232
2520464
2520444
Qty. Description
AR
1
1
1
1
2
1
1
Line, Fuel
Cap, Gas Tank
Gasket
Asm., Fuel Line, Tank to Filter
Mount, Fuel Filter
Bolt
Filter, Fuel
Asm., Fuel Line, Filter to Rail
10/04
B4
CONTROLS
1
2
4
6
Ref. Part No.
2010238
1 7517899
2 2202725
3 2201836
Qty. Description
Ref. Part No.
1 Asm., Master Cylinder

2 Screw, Torx
1 Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
4 2201833
5 2202410
6 2201835
Qty. Description
1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)
1 Kit, Piston
(Incl. Piston, Seals, Boot, Spring)
1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
7/04
B5
BRAKE, FRONT
3
10
5
6
Ref. Part No.
1910841
1910842
1930665
1 7515489
2 5134639
5134640
1930642
3 5410494
Qty. Description
1
1
1
1
1
1
1
1
Asm., Brake Caliper, LH (Incl. 1-6,8,9)

Asm., Brake Caliper, RH (Incl. 1-6,8,9)
Kit, Piston and Seal (Incl. 4-6)
Screw, Socket Set
Caliper, Brake, LH
Caliper, Brake, RH
Kit, Front Brake Boot
Boot, Pin Seal
Ref. Part No.
4
5
6
7
8
9
10
5410780
5410779
5132294
2202412
1910411
5410495
7080352
Qty. Description
1
1
1
1
1
1
1
Ring, Molded Square, .103 x .134

Ring, Molded Square, .094
Piston, Brake, Long
Kit, Asm., Front Brake Pad
Asm., Mount, Caliper
Boot, Bushing
Screw, Bleeder
8/04
B6
BRAKE LINES, FRONT

1
2
3
4
10
9
8
5
6
2
7
2
Ref. Part No.
1
2
3
4
5
5410988
1910499
1910883
7052292
1910839
Qty. Description
6
3
1
1
1
Seal
Bolt, Banjo
Line, Brake
Fitting, Cross (Junction Block)
Line, Brake, Right Front
Ref. Part No.
6
7
8
9
10
8360031-40
7080138
1910838
7512024
4110164
Qty. Description
1
4
1
2
1
Conduit
Cable Tie
Line, Brake, Left Front
Screw
Switch, Stoplight
8/04
B7
CALIPER, REAR
4, 5
3
5
3
4, 5
6
7
1, 3
1
1, 3, 7
Ref. Part No.
1910690
1 2201873
2 1910538
3 2201870
Qty. Description
1
1
2
1
Ref. Part No.
Asm., Caliper
Kit, Anvil Body
Fitting, Bleed, Compact
Kit, Slide Bolt
4
5
6
7
2201872
2201869
1910529
2202414
Qty. Description
1
1
1
1
Kit, Seal
Kit, Piston and Seal
Bracket, Caliper
Kit, Asm., Brake Pad
3/04
B8
MASTER CYLINDER, REAR and FOOT PEDAL

10
15
11
1
2
14
12
16
13
4
7
17
18
19
20
21
22
22
23
23
25
14
26
24
Ref. Part No.
2202709
2202644
1 ------2 5410988
3 1910801
1910805
4 1910499
5 7558402
6 7552901
7 7512365
8 7670126
9 7517756
10 7080138
11 7621462
Qty. Description
1 Kit, Brake Line, Rear

(Foot)(Incl. 2,4,18)
1 Kit, Brake Line, Rear (Hand)(Incl. 2-4)
1 Asm., Caliper
(See Rear Caliper Pg. B8 for Details)
4 Seal
1 Line, Brake, Rear (Hand)
1 Line, Brake, Hardline
2 Bolt, Banjo
2 Washer, Flat
2 Washer, Spring Lock
2 Screw, Cap
1 Clip, Retaining
1 Screw
3 Cable Tie
3 Rivet
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
7080960
7080003
7517386
1930854
1910438
1910790
1910766
7042075
7515158
7661401
7555919
5433189
1013415-067
7041750
1013414-067
Qty. Description
3
2
4
1
1
1
1
1
2
1
2
2
1
1
1
Clamp, Cable
Clamp, Hose
Screw
Asm., Reservoir, Brake, Rear
Hose, Reservoir
Asm., Master Cylinder, Brake, Rear
Line, Rear Brake, Foot
Spring
Screw
Pin, Cotter
Washer
Bushing, Pivot, Pedal
Rod, Brake, Black
Spring, Torsion
Mount, Brake, Black
7/04
B9
CONTROLS - THROTTLE ASM./CABLE


1
2
3
5
4
Ref. Part No.
1 5410193
2 5434113
3 5411439
Qty. Description
1 O-Ring
1 Cover, Throttle Control
1 O-Ring
Ref. Part No.
4 7081220
5 2010230
6 2010191
Qty. Description
1 Cable, Throttle
1 Asm., Throttle Control (Incl. 6)
1 Asm., Throttle Clamp
8/04
B10
DRIVE SHAFT, FRONT

3
6
Ref. Part No.
1380234
1 7670092
2 1590395
3 7710557
Qty. Description
2
2
2
2
Asm., Drive Shaft, Front

Circlip
Joint, CV (Inner)
Kit, Circlip
Ref. Part No.
4 2202826
5 2201015
6 1590396
Qty. Description
2 Kit, Boot
(Inner)(Incl. Clamps and Grease)
1 Kit, Boot
(Outer)(Incl. Clamps and Grease)
1 Joint, CV (Outer)
7/04
B11
DRIVE SHAFT, REAR


1
10
Ref. Part No.
1
2
3
4
5
1380240
1590325
1350044
1350046
1350045
1350043
Qty. Description
2
1
2
1
2
2
Asm., Drive Shaft, Rear (Incl. 1-8)

CV Joint
Clamp, Large
Grease, 30g
Boot
Clamp, Small
Ref. Part No.
6
7
8
9
10
1350047
1590281
1350042
2202904
2201373
Qty. Description
1
1
1
1
1
Grease, 50g
Joint, Plunging
Ring, Spring
Kit, Boot, Replacement
Boot, Wheel Side
7/04
B12
PROP SHAFT, FRONT


3
2
4
Ref. Part No.
1380221
1 7661913
2 3260133
3 2202015
Qty. Description
1
1
1
2
Asm., Front Prop Shaft

Pin, Spring
Yoke
Kit, Cross and Bearing
Ref. Part No.
4
5
6
7
1350089
3260131
7080424
5411092
Qty. Description
1
1
1
1
Asm., Shaft, Bar

Yoke
Fitting, Lubrication
O-Ring
7/04
B13
PROP SHAFT, REAR

Ref. Part No.
1380208
1 1350039
2 1380179
Qty. Description
1 Asm, Prop Shaft, Rear

3 Yoke, Prop Shaft, Rear
1 Shaft, Rear
Ref. Part No.
3 2202015
4 7661913
Qty. Description
2 Kit, Cross and Bearing

1 Pin, Spring
7/04
B14
HANDLEBAR and HEADLIGHT POD

29
6
30
31
28
34
4
5
6
32
7
33
26
25
8
24
21
9
11
23
10
22
12
13
14
14
20
19
18
15
13
17
16
C1
27
HANDLEBAR and HEADLIGHT POD

Ref. Part No.
1 4011074
2 5435680-455
5435364-473
5435364-293
3 5434380
4 3280431
5 5412138
6 7511881
7 ------8
9
10
11
12
13
Qty. Description
1
1
1
1
1
1
1
3
1
7080138
7670127
5410163
5412330
5433534
4011002
4010278
3
1
2
1
1
1
1
4010321
14 5435365-070
5435365-177
1
1
Switch, Worklight, On/Off

Pod, Headlight, Upper, NBU Camo (AC)
Pod, Headlight, Upper, Venom (AU)
Pod, Headlight, Upper, Indy Red (AW)
Bezel
Asm., Cluster
Mount, Rubber
Screw
Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B10, Ref. 5)
Cable Tie
Clip, Screw
O-Ring
Grommet
Cover, Key
Switch, Key, 3 Position (Incl. Key)
Blank, Key, Series 2000, 2100, 6700,
6800
Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating
it with your existing key.
Pod, Headlight, Lower, Black (AC)
Pod, Headlight, Lower, Black Metallic
(AU)(AW)
Ref. Part No.
Qty. Description
15
16
17
18
19
20
21
22
23
24
25
26
7517658
5132382
4010298
7542122
5435661
8360011-15
4010638
7517317
5244969-067
5631516
5631517
-------
1
1
1
4
1
AR
1
2
1
1
1
1
27
28
29
30
31
32
33
34
5432952
7517625
5433834-070
4010591
5433903
5242987-067
7515189
2410429
4010253
1
1
2
1
1
1
4
1
1
Screw
Cap, Hall Sensor
Sensor, Hall Effect
Nut, Nylok
Plug, Steering Post
Tubing, Convoluted
Receptacle, Pod Mount
Screw
Bracket, Pod Mounting, Black
Block, Handlebar
Block, Handlebar, Pegged
Asm., Master Cylinder
(See Controls Pg. B5 for Details)
Plug, Hole
Screw, Set
Grip, Handlebar, Black
Switch, Handlebar, Hi/Lo/Mode
Spacer, Switch, LH
Tube, Handlebar, Black
Screw
Asm., Headlight
Bulb, Headlight
10/04
C2
STRUT, FRONT
1
2

16
22
8
21
17
11
20
19
18
16
11
13
14
15
11
10
12
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7547104
7555749
5810291
5432872
5132062
5432871
5243364
7043116-067
7043116-293
5412665
7515339
7558402
5134154
1822653
5134155
1822654
Qty. Description
2
2
2
2
2
2
2
2
2
2
4
10
1
1
Nut
Washer
Spacer, Rubber
Ball, Pivot, Top
Spacer
Ball, Pivot, Bottom
Retainer, Spring
Spring, Compression, Black (AC)
Spring, Compression, Red (AU)(AW)
Bumper
Bolt
Washer, Flat
Support, Hubstrut, LH
Asm., Hubstrut, LH
(Incl. 10,11,16, and from A-Arm/Strut
Mounting Pg. C7, Ref. 2-5)
1 Support, Hubstrut, RH
1 Asm., Hubstrut, RH
(Incl. 10,11,16, and from A-Arm/Strut
Mounting Pg. C7, Ref. 2-5)
Ref. Part No.
Qty. Description
13
14
15
16
17
7710507
3514342
7080306
7542324
-------
2
2
2
4
1
18
19
20
21
22
7552901
7512365
7080367
5211115
7041762
4
4
2
2
2
Ring, Retaining
Bearing, Hubstrut
Fitting, Lubrication
Nut, Nylok
Asm., Brake Caliper
(See Front Brake Pg. B6 for Details)
Washer, Spring Lock
Screw, Cap
Clamp, Cable
Washer
Strut, Front
10/04
C3
WHEEL, FRONT
7
6

4
2
3
10
12
11
Ref. Part No.
1
2
3
4
5
6
5412660
1520269-067
5411164
7661401
7556004
5134310
Qty. Description
2
2
2
2
2
2
Tire, Front, 26x8-12

Rim, Front, Black
Cover, Dust, Hub
Pin, Cotter
Washer
Hub, Wheel
Ref. Part No.
7
8
9
10
11
12
7515513
5244314
7512325
7542810
1525017
7547237
Qty. Description
8
2
8
2
2
8
Stud
Disc, Brake, Front
Bolt
Nut, Slotted
Valve, Rim
Nut, Flange
10/04
C4
WHEEL, FRONT
6
5
4
1
10
11
Ref. Part No.
1
2
3
4
5
6
5412660
7547309
1520898
7661401
5134310
7518378
Qty. Description
2
8
2
2
2
8
Tire, Front, 26x8-12

Nut, Wheel
Rim, Front
Pin, Cotter
Hub, Wheel
Stud
Ref. Part No.
7
8
9
10
11
5244314
7512325
7556004
7542810
1525017
Qty. Description
2
8
2
2
2
Disc, Brake, Front

Bolt
Washer
Nut, Slotted
Valve, Rim
10/04
C5
TAILLAMPS/WORKLAMPS/HEADLIGHTS

1
8
10
7
9
4
3
Ref. Part No.
1 2410427
2410428
2 7670054
3 7517561
4 7670112
5 2410425
2410426
Qty. Description
1
1
4
2
2
1
1
Asm., Taillight, LH
Asm., Taillight, RH
Nut, Push-On
Screw
U-Nut
Asm., Headlight, LH
Asm., Headlight, RH
Ref. Part No.
6
7
8
9
10
4030048
4011102
4011065
4011101
4011064
Qty. Description
2
2
2
2
2
Bulb, High Beam

Socket, Worklight
Bulb, Worklight
Socket, Taillight
Bulb, Tail/Stop
7/04
C6
A-ARM and STRUT MOUNTING

24
1
2

25
26
28
3
4
26
28
25
24
23
27
22
6
7
21
8
9
10
18
11
19
20
17
12
8
15
13
16
14
Ref. Part No.
1 ------2
3
4
5
6
7
8
9
10
11
12
13
7080927
5211121
5410548
7512284
2202865
2202866
7542438
7661203
5435028-070
5435029-070
7512084
7517909
7556099
7547177
Qty. Description
1 Support, Hubstrut
(See Front Strut Pg. C3, Ref. 12)
2 Joint, Ball
2 Bracket, Ball Joint
2 Boot, Rubber
4 Bolt, Socket
1 Kit, A-Frame, LH (Incl. 8,24,25,27,28)
1 Kit, A-Frame, RH (Incl. 8,24,25,27,28)
2 Nut, Castle
4 Pin, Cotter
1 Shield, CV Front, Black, LH
1 Shield, CV Front, Black, RH
6 Screw
2 Bolt
4 Washer
2 Nut
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
5411920
7061054
7547028
5134242
7542711
7061034
5411291
1821498
7515415
7542439
7512492
7552603
7555832
5133806
5434551
Qty. Description
1
2
2
2
2
2
2
2
2
2
4
4
4
2
4
Boot, Seal, Rod End

Rod End, LH
Nut, Jam, LH
Tie Rod
Nut, Jam
Rod End, RH
Boot, Seal, Rod End
Asm., Tie Rod (Incl. 15-20)
Screw
Nut, Nylok
Screw
Washer, Spring Lock
Washer
Shaft, A-Arm
Bushing, A-Arm, Long
7/04
C7
STEERING POST
2
1
3
10
3
4
5
6
5
10
Ref. Part No.
1
2
3
4
5
7517428
5246732
5433866
1822630-067
7556162
Qty.
4
1
2
1
2
Description
Ref. Part No.
Bolt
Bracket, Upper, Bushing
Bushing, Upper
Post, Steering, Black
Bushing
6
7
8
9
10
5222393
3514352
7547158
7661633
7542343
Qty.
1
1
1
1
4
Description
Flangette
Bearing
Nut, Slotted, Hex
Pin, Cotter
Nut, Flange
7/04
C8
GEAR SELECTOR
4
1

2
3
5
11
10
Ref. Part No.
1
2
3
4
5
6
5412003
7512024
5411007
7542122
7515175
1821055
Qty. Description
1
1
1
2
2
1
Cover, Shift Knob

Screw
Knob, Gear Selector
Nut, Nylok
Bolt
Asm., Linkage Rod
Ref. Part No.
7
8
9
10
11
1013315-067
7542324
8360012-10
5435042
7518342
Qty. Description
1
2
1
2
2
Selector, Gear, Black

Nut, Nylok
Trim, Edge
Mount, Gear Selector
Bolt, Flange
7/04
C9
DRIVE CLUTCH
5
1
4
2
6
7
2
10
5
13 12
14
11
Ref. Part No.
1
2
3
4
5
6
7
1321971
1520836
7556335
5631674
7541906
5431936
5020422
3514492
Qty. Description
1
1
2
1
3
6
3
1
Asm., Drive Clutch (Incl. All Less 10,14)

Asm., Clutch, Drive
Washer, Clutch
Spacer
Nut, FLEXLOC
Button, Clutch
Pin, Roller
Bearing
Ref. Part No.
8
9
10
11
12
13
14
3576510
7518062
7041157
1321622
5430945
7512266
5631698
Qty. Description
1
6
1
3
6
3
3
Cover, Bearing
Screw
Spring, Clutch
Asm., Roller and Bushing
Washer
Bolt, Shoulder
Weight, Shift, 20-60
10/04
C10
DRIVEN CLUTCH
13
14
12
11
10
15
4
5
16
17
9
18

19
20
21
7
6
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
7556120
1322515
5248227
7552901
7515382
3234205
3234204
3234203
3234200
3211106
3234206
Qty. Description
AR
1
1
1
1
1
1
1
1
1
1
Bushing
Asm., Driven Clutch (Incl. 3-6,18)
Washer, Domed
Washer, Spring Lock
Bolt
Ring, Retaining
Ring, Retaining
Bearing, Ball
Washer, Thrust
Belt, Drive
Dampener, Spider
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
3234196
3234234
3234192
3234194
3234207
3234195
3234233
3234201
3234197
3234202
Qty. Description
2
1
4
1
2
2
1
2
2
2
Washer, Thrust
Asm., Cam
Screw, Cap
Ring, Retaining
Roller, Clutch
Ring, Retaining
Spring, Compression, Green/White
Pin, Roller
Roller, Clutch
Pin, Spring Slotted
10/04
C11
CLUTCH COVER
7
5
4
8
3
10
12
11
13
14
15
16
Ref. Part No.
1
2
3
4
5
6
7
8
2201955
7517599
5521578
5434255-070
5410542
5434264
5411489
7080707
Qty. Description
1
5
1
1
1
1
1
2
Kit, Inner Clutch Cover (Incl. 12)

Asm., Bolt/Washer
Seal, Cover, Clutch, Outer
Cover, Clutch, Outer, Black
O-Ring
Plug, Drain
Boot, Duct
Clamp, Narrow Band
Ref. Part No.
9
10
11
12
13
14
15
16
5435976
7172747
7172563
7512094
7517867
5244527-067
5411918
5412675
Qty. Description
1
1
1
9
3
1
1
1
Duct, Clutch Outlet

Decal, Automatic Transmission, EBS
Decal, Warning, Clutch Cover
Screw
Screw
Bracket, Retainer, Seal, Black
Seal, Cover, Clutch, Inner
Stopper, Inner Clutch Cover
10/04
C12
WHEEL, REAR
11
10
9

8
7
5
12
6
13
15
14
Ref. Part No.
1
2
3
4
5
6
7
8
5412661
1520457-067
5411164
7543005
7661404
7555796
5134311
7515513
Qty. Description
2
2
2
2
2
4
2
8
Tire, 26x11-12
Rim, Rear, Black
Cover, Dust, Hub
Nut, Castle
Pin, Cotter
Washer, Cone
Hub, Rear Wheel
Stud
Ref. Part No.
9 7710440
10 3585502
11 - - - - - - 12
13
14
15
7512325
5244635
1525017
7547237
Qty. Description
2 Ring, Retaining
2 Bearing
2 Carrier, Wheel Bearing (See Rear Suspension Pg. D2, Ref. 11)
8 Bolt
2 Disc, Brake, Rear
2 Valve, Rim
8 Nut, Flange
10/04
C13
WHEEL, REAR
11
10
9

7
8
12
5
4
6
13
14
Ref. Part No.
1
2
3
4
5
6
7
8
5412661
7547309
1520899
7543005
7661404
7555796
5134311
7518378
Qty. Description
2
8
2
2
2
4
2
8
Tire, 26x11-12
Nut, Wheel
Rim, Rear
Nut, Castle
Pin, Cotter
Washer, Cone
Hub, Rear Wheel
Stud
Ref. Part No.
9 7710440
10 3585502
11 - - - - - - 12 7512325
13 5244635
14 1525017
Qty. Description
2 Ring, Retaining
2 Bearing
2 Carrier, Wheel Bearing (See Rear Suspension Pg. D2, Ref. 11)
8 Bolt
2 Disc, Brake, Rear
2 Valve, Rim
10/04
C14
SUSPENSION, REAR
2
18
1
7
8
36
38
18
37
9
8
29
34
28
37
25
18
25
31
33
18
36
26
23
35
10
27
31
22
28
32
21
30
20
29
8
7
11
12
19
13
14
15
18
16
17
D1
24
SUSPENSION, REAR
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
7518341
7542343
7555939
5434549
5334114-067
1580107-067
7517231
7555761
5432598
5020827
5134206
5631142
5434550
7552614
7555740
7517873
7515415
7542439
7041959
5631014
5435273
7042311-067
7042311-293
23 5630885
Qty. Description
6
6
2
2
1
2
4
8
8
2
2
4
8
4
4
4
2
10
2
2
2
2
2
Bolt, Flange
Nut, Flange
Washer
Bushing, Stabilizer Tube
Bar, Stabilizer Tube, Black
Arm, Stabilizer Bar, Black
Screw
Washer
Bushing, Stabilizer, Link
Rod, Linkage, Stabilizer
Carrier, Wheel Bearing
Bushing, Bearing Carrier
Bushing, Control, Lower
Washer, Lock
Washer
Bolt
Screw
Nut, Nylok
Shock, Rear
Cam, Adjusting, Spring
Sleeve, Shock Protector
Spring, Compression, Rear, Black (AC)
Spring, Compression, Rear, Red
(AW)(AU)
2 Retainer, Spring
Ref. Part No.
Qty. Description
24 7515433
25 5020826
26 1014320-067
1014321-067
1014320-293
2
6
1
1
1
1014321-293
5245140-067
7552603
7512492
7555832
5434551
1014174-067
1014175-067
1014174-293
1
4
4
2
4
1
1
1
1014175-293
27
28
29
30
31
32
33 7512084
34 5434890-1038
5434891-1038
35 5133806
36 7515472
37 5434548
38 1541801-067
4
1
1
2
6
12
1
Screw
Shaft, A-Arm, Short
Arm, Control, Upper, Black, LH (AC)
Arm, Control, Upper, Black, RH (AC
Arm, Control, Upper, Red, LH
(AW)(AU)
Arm, Control, Upper, Red, RH
(AW)(AU)
Strap, Black
Washer, Spring Lock
Screw
Washer
Bushing, A-Arm, Long
Arm, Control, Lower, Black, LH (AC)
Arm, Control, Lower, Black, RH (AC)
Arm, Control, Lower, Red, LH
(AW)(AU)
Arm, Control, Lower, Red, RH
(AW)(AU)
Screw
Shield, CV, Rear, Black, LH
Shield, CV, Rear, Black, RH
Shaft, A-Arm
Bolt
Bushing, A-Arm, Short
Support, Stabilizer, Black
11/04
D2
ELECTRICAL

10
24
25
8
20
12
7
23
21
22
11
13
19
14
15
18
17
29
16
32
33
28
27
26
31
30
33
3
36
35
1
34
37
D3
39
38
ELECTRICAL
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2410528
2410587
2410535
5435696
7555859
7512232
4011224
2202099
5247376
5432077
4011139
4011286
4011072
5432302
7080399
4011141
4011109
7547283
7552801
7512084
Qty. Description
1
1
1
1
2
4
1
1
1
AR
1
1
1
1
1
2
1
2
2
2
Harness, Main
Harness, Jumper
Harness, Winch
Box, Battery
Washer, Flat
Bolt
Battery
Kit, Battery Bolt
Strap, Battery Holddown
Tube, Vent
Cable, Battery/Frame
Cable, Battery/Solenoid
Switch, Magnetic
Clip
Bushing
Relay
ECU
Nut, Hex, Jam
Washer, Spring Lock
Screw
Ref. Part No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
4010376
5248725
5133658
4010425
7542151
4011060
4011059
7518322
7080585
2410365
2410364
2410363
7512024
7080492
4020149
7080965
7080138
4011100
5248725
Qty. Description
1
1
1
1
1
1
1
2
1
2
1
1
9
6
1
2
11
1
1
Cable, Solenoid/Starter
Bracket, Mount, Regulator
Spacer, Coil
Coil, EFI
Nut
Wire, Spark Plug
Wire, Spark Plug
Screw
Clamp
Fuse, Self Resetting, 20 Amp
Screw
Cable Tie
Clip, Rosebud
Mount, Cable Tie
Cable Tie
Regulator, Volt
Bracket, Voltage Regulator
10/04
D4
TRANSMISSION MOUNTING

9
12
10
11
3
4
5
5
7
Ref. Part No.
1
2
3
4
5
6
8450003-1525
7052075
7080307
7080756
7547263
7517632
Qty. Description
AR
1
2
2
6
2
Line, Fuel
T-Fitting
Clamp, Hose
Clip, Snap In
Nut, Nylok
Screw
Ref. Part No.
7
8
9
10
11
12
D5
1013134-067
7517289
7518415
5247348
7542343
7512377
Qty. Description
1
4
2
1
2
2
Mount, Rear Engine, Black

Screw
Bolt, Flange
Bracket, Mount, Rear Transmission
Nut, Flange
Bolt, Carriage
7/04
HOUSING, FRONT
1
2

3
4
16
13
6
15
28
14
15
12
27
11
16
10
26
25
20
19
18
17
21
4
24
22
23
15
Ref. Part No.
1341497
3233955
1 3234163
2 3234159
3
4
5
6
7
8
9
10
11
12
13
3234161
3233926
3233953
3233928
3234166
3234167
------3233957
3234169
7080307
8450003
7512024
Qty. Description
1
1
1
1
1
2
1
1
1
1
1
14
1
1
AR
1
Asm., Front Gearcase

Kit, Bolt
Screw, Set
Asm., Cover Plate
(Incl. Output Cover, Insert and Coil)
Shim, Armature Plate
Bearing, Roller Ball
Asm., Race/Output Hub (Incl. 25)
Pin, Dowel
Clutch Housing/Ring Gear
Asm., Roll Cage (Incl. Spring and Roll Cage)
Spring
Kit, Roller
Bushing
Clamp, Hose
Line, Fuel
Screw
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
D6
7080693
3233956
3233918
3233947
3234112
3233944
------------3233942
7518364
3233951
3233929
3234168
3234162
3234160
Qty. Description
1
1
11
1
1
1
1
1
1
4
1
1
1
1
1
Clamp, Hose
Kit, Minor Repair (Incl. O-Rings and Seals)
Screw
Cover, Input
Bearing, Roller Ball
Shaft, Pinion, 11T
Bushing
Gearcase, LH
Plug, Oil Fill
Bolt, Flange
Asm., Drain Plug (Incl. Plug and Washer)
Bearing, Needle, Roller Thrust
Asm., Clutch (Incl. 7-9)
Ring, Retaining
Plate, Armature
7/04
GEARCASE
19
18
16
17
20
15
21
14
13
12
26
22
25
23
27
26
24
10
25
11
8
4
28
48 15
68 67
71
64
66
65
70
69
40
35 39
30 29 38
33 31
35 37 32
63
48 16
62
60
61
49
12
50
29
35
32 34
30 31 33
36
12
47
51
52
59
58
53
41
45
54
55
56
18
8
57
15
D7
46
44 43 42
12
GEARCASE
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1341470
3233961
3233826
3234124
3234123
3233869
3233829
3233831
3233788
3233832
3234143
3234128
3233018
3233036
3234133
3233019
3233247
3234127
3233846
3233874
3234042
3234142
3233910
3233548
3233524
3233858
3233859
3233860
3233915
3234040
3234144
3233875
3233850
3233851
3233852
3233718
Qty. Description
1
1
8
1
1
1
1
1
2
1
1
1
4
1
1
4
4
1
15
1
2
1
1
1
1
2
2
1
1
1
2
3
2
2
1
2
Asm., Gearcase
Nut
Screw
Cover
Gasket
O-Ring
Pawl, Detent
Shaft, Shift
Seal
Gear, 31T
Label, Oil Fill/Level Check
Gearcase, Main
Bearing
Chain, Silent
Shaft, Input
Bearing
Pin, Dowel
Cover, Main, LH
Screw
Seal, Dual Lip
Screw
Bracket, Transmission Mount
Drum, Shift
O-Ring
Tube, Vent
Fork, Shift
Pin, Dowel
Rail, Shift Shaft
Plate, Park
Engagement Dog
Spring, Wave
Engagement Dog
Ring, Retaining
Washer
Gear, 33T
Bearing, Needle
Ref. Part No.
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
3233853
3233854
3233855
3234135
3234136
3234137
3234086
3234122
3233106
3233357
3234055
3234140
3233794
3233619
3233873
3233621
3233911
3233582
3233583
3233611
3234130
3233625
3233784
3233844
3233552
3234013
3233917
3234043
3233839
3233838
3234082
3233076
3233830
3233835
3233834
3233906
Qty. Description
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
AR
AR
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
Shaft, Reverse
Sprocket, 24T
Washer
Gear, 23T
Gear, 51T
Gear, 56T
Screw
Cover, Bearing
Ring, Snap
Spacer
Bearing, Ball
Shaft, Pinion, 10T
Plug
Washer, Thrust
Sprocket, 22T/18T
Gear, 31T
Shaft, Output, Main, Rear
Button, Thrust
Shim
Shim
Cover, Output, Front
Shaft, Output, Front
Chain, Silent
Sprocket, 22T
Bushing
Clamp, Tie
Lockout, Park
Nut
Gear, 16T
Disc, Lockout
Star, Detent
O-Ring
Spring, Compression
Switch
Ring, Retaining
Bellcrank
8/04
D8
GEARCASE, REAR
17
16
15
14
13
12
11
10
Ref. Part No.
1
2
3
4
5
6
7
8
1341498
3234117
3233524
3234116
3234117
3233268
3234115
3234087
3233878
Qty. Description
1
6
1
1
2
2
1
2
2
Asm., Gearcase, Rear

Pin, Dowel
Tube, Vent
Cover, Rear, LH
Pin, Dowel
Bearing, Ball
Gearcase, Rear, RH
Plug, Hex, Flange
Seal, Triple Lip
Ref. Part No.
9
10
11
12
13
14
15
16
17
3234003
3234158
3233714
3233881
3233577
3233879
3233581
3233582
3233583
Qty. Description
1
1
1
1
1
1
AR
1
AR
Seal, Triple Lip

Ring, Retaining
Bearing, Ball
Shaft, Pinion, 10T
Bushing
Gear, 31T
Shim
Button, Thrust
Shim
7/04
D9
GEARCASE MOUNTING, REAR

2
1
3
4
6
2
Ref. Part No.
Qty. Description
Ref. Part No.
1 7518365
2 7512492
3 7517878
4 Bolt, Flange
6 Screw
5 Screw
4 7555806
5 7547008
6 7547180
Qty. Description
12 Washer, Flat
5 Nut, FLEXLOC
4 Nut, Flange
7/04
D10
CRANKCASE and CRANKSHAFT

1
2
33
28
5
26
29
28
27
7
8
30
31
26
9
25
10
24
23
11
12
13
14
22
15
21
16
19
17
18
D11
32
20
CRANKCASE and CRANKSHAFT

Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7518007
7661175
7051530
7663001
5132753
5134837
5412114
3514361
3514318
7556194
2202916
7516603
5812016
7710512
1202663
3060004
7517792
Qty. Description
1
2
1
2
4
1
1
1
1
1
1
1
1
1
1
1
6
Plug
Dowel
Plug
Pin, Dowel
Bearing
Shaft, Balance
Seal
Bearing, Ball
Bearing, Ball
Bushing
Kit, Crankshaft
Bolt
Seal, O-Ring
Ring, Retaining
Asm., Oil Pickup
Plug
Screw
Ref. Part No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
7517793
2202864
7052306
5812232
3585704
7721117
5211785
7518045
7517865
7555982
2202145
7721131
7556183
7517598
5244286
2202918
Qty. Description
9
1
1
1
2
1
1
5
2
1
1
1
1
3
1
1
Screw
Kit, Crankcase
Plug, Socket
Washer, Copper
Bearing
Key, Woodruff
Plate, Baffle
Screw
Screw
Washer
Kit, Gear Set
Key, Woodruff
Washer, Spring
Screw
Plate, Thrust
Kit, Camshaft
10/04
D12
MANIFOLD and THERMOSTAT

2
3
4
5
Ref. Part No.
1 4010644
2 5411521
3 7052352
Qty. Description
1 Sensor, Thermister
1 O-Ring
1 Thermostat w/Bypass
Ref. Part No.
4 5631390
5 7516822
Qty. Description
1 Cover, Thermostat w/o Bypass

9 Screw
8/04
D13
PISTON and CYLINDER

2
10
3
9
5
6
Ref. Part No.
1
2
3
4
5
2202917
5247359
7661175
7051534
3021510
-------
Qty. Description
2
1
2
1
4
2
Kit, Piston (Incl. 4-6)

Gasket, Head
Dowel
Plug
Circlip, Piston
Pin, Piston
Ref. Part No.
6
7
8
9
10
D14
2202920
5247360
5134152
2202696
5132402
Qty. Description
1
1
4
1
4
Kit, Piston Ring

Gasket, Base
Lifter, Valve
Kit, Cylinder (Incl. 3)
Pushrod
10/04
THROTTLE BODY MOUNTING

2
3
4
5
6
14
7
8
9
10
11
13
12
Ref. Part No.
1
2
3
4
5
6
7
7516822
5134427
5248146
5412730
5432533
7517277
3070195
Qty. Description
9
1
1
1
1
3
2
Screw
Cover, Valve
Plate, Breather
Gasket, Breather
Cover, Breather
Screw
Plug, Spark, Champion RC7YC
Ref. Part No.
8
9
10
11
12
13
14
1253564
7517666
7081193
1202836
7517384
2410513
5412632
Qty. Description
1
2
1
1
1
1
1
Adapter, Throttle Body

Screw
Clamp, Hose
Asm., Body, Throttle
Screw
Sensor, Crank Position
Seal, Valve Cover
10/04
E1
INTAKE

2
3
4
5
6
7
10
9
8
Ref. Part No.
1
2
3
4
5
7518274
1202169
5131413
5910042
7042336
Qty. Description
6
4
4
8
4
Bolt
Asm., Arm, Rocker
Retainer, Spring
Retainer, Lock
Spring, Valve
Ref. Part No.
6
7
8
9
10
E2
5411895
3021539
5135009
5134662
5132696
Qty. Description
4
1
4
2
2
Seal, Valve Guide

Head, Cylinder
Stud
Valve, Exhaust
Valve, Intake
10/04
DIPSTICK and OIL FILTER

1
3
4
5
6
12
7
8
11
10
9
Ref. Part No.
1
2
3
4
5
6
1203079
1202881
5245805
7517795
7516824
7556005
Qty. Description
1
1
1
2
1
1
Asm., Dipstick
Tube, Oil Fill
Clamp
Screw
Screw
Washer
Ref. Part No.
7
8
9
10
11
12
E3
7042203
7661127
2540086
2540115
7518007
5412688
Qty. Description
1
1
1
1
1
1
Spring, Pressure Relief

Pin, Dowel
Filter, Oil
Nipple, Oil Filter
Plug, Socket
O-Ring
10/04
OIL PUMP and WATER PUMP

1
2
3
4
5
6
7
9
10
11
12
13
14
15
Ref. Part No.
1
2
3
4
5
6
7
2202699
1202588
5133852
3584404
7710531
5133948
5134388
7517807
Qty. Description
1
1
1
1
1
1
1
4
Kit, Oil Pump (Incl. 1-6)

Asm., Gerotor
Housing, Oil Pump
Bearing, Ball
Ring, Retaining
Shaft, Oil/Water Pump
Gear, Driven, Water/Oil
Screw
Ref. Part No.
8
9
10
11
12
13
14
15
5812511
5433684
7555874
7546804
3610075
5812571
5631389
7516822
Qty. Description
1
1
1
1
1
1
1
5
Gasket, Cover, Magneto

Impeller, Water Pump
Washer, Flat
Nut, Hex, Nylok
Seal, Water Pump
Seal, Water Pump
Cover, Water Pump
Screw
8/04
E4
FUEL INJECTOR
Ref. Part No.
1 1202863
2 2520451
3 7516730
Qty. Description
Ref. Part No.
Qty. Description
2 Asm., Fuel Injector

1 Fuel, Rail Dual Point
1 Asm., Screw and Washer
10/04
E5
MAGNETO

4
5
15
14
7
8
13
12
10
11
Ref. Part No.
1
2
3
4
5
6
7
8
5412048
5412455
1200002
4010911
7517848
7555907
5412458
1202513
Qty. Description
Ref. Part No.
1
1
1
1
3
1
1
1
9
10
11
12
13
14
15
Seal, Flanged
Seal, Oil
Asm., Engine Cover, Magneto
Stator
Screw
Washer
O-Ring
Asm., Cover, Stator
5812283
5435099
7517950
7547213
4010912
7517950
5245364
Qty. Description
1
1
12
1
1
4
1
Cover, Sound Dampening

Cover, Stator, Outer
Screw
Nut
Flywheel
Screw
Bracket, Stator, Wire Holddown
8/04
E6
STARTING MOTOR

3
1
7
6
Ref. Part No.
1
2
3
4
7517868
7516823
4010417
4010418
Qty. Description
1
1
1
1
Ref. Part No.
Bolt
Screw
Starter
Asm., Bendix
5 7555908
6 7546705
7 7552616
E7
Qty. Description
2 Washer
1 Nut
1 Washer, Lock
8/04
TOOL KIT
1
2
9
3
8
6
Ref. Part No.
1
2
3
4
2874735
2870725
-------------------
Qty. Description
1
1
1
1
1
Ref. Part No.
Kit, Tool (Incl. 1-7)

Gauge, Tire Pressure
Screwdriver
Wrench, 8-10 Open
Wrench, 9/16 x 1 1/2 Open
5
6
7
8
9
E8
------------2682572
2873647
9917720
Qty. Description
1
1
1
1
1
Wrench, Plug
Puller, Spark Plug (Wrench Handle)
Pouch, Tool Kit
Wrench, Torx
Owners Manual, 05 Sportsman 800 EFI
10/04
PRINTED IN THE USA
PARTS MANUAL PN 9917721 and MICROFICHE PN 9917722 10/04
cover
toc
Changed pages in 9917721
10
10
11
11
12
12
13
13
14
14

2005 Sportsman 800 Efi - A05mh76ac, Au, Aw - PM

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PARTS MANUAL PN 9917721 and MICROFICHE PN 9917722 10/04

SPORTSMAN 800 EFI

BRAKE LINES, FRONT . . . . . . . . . . . . . B7

HEADLIGHT POD . . . . . . . . . . . . . . . . . . C1--2

RACK MOUNTING, REAR . . . . . . . . . . . A6

CAB, REAR and SEAT

E 2004 Polaris Sales Inc.

CAB, REAR and SEAT

Ref. Part No.

E 2004 Polaris Sales Inc.

Cover, Front, NBU Camo (AC)

Ref. Part No.

RACK MOUNTING, REAR

E 2004 Polaris Sales Inc.

Ref. Part No.

STORAGE, FRONT and BUMPER MOUNTING

STORAGE, FRONT and BUMPER MOUNTING

Ref. Part No.

Panel, Bumper, Front, Black

STORAGE BOX, REAR

E 2004 Polaris Sales Inc.

Ref. Part No.

Box, Storage, Rear, Upper

E 2004 Polaris Sales Inc.

Decal, Reflector, Red

Ref. Part No.

Decal, Rear Cab, AWD, LH

Decal, Reflector, Red

Ref. Part No.

Decal, Reflector, Amber, LH

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

1 Kit, Short Block, 800 EFI NOTE: The

Ref. Part No.

Mount, Rubber, Rear

E 2004 Polaris Sales Inc.

Filter, Preclean Sleeve

Ref. Part No.

Sheath, Reflective Sleeve

E 2004 Polaris Sales Inc.

Ref. Part No.

Ref. Part No.

1 Asm., Master Cylinder

1 Kit, Master Cylinder Clamp

Asm., Brake Caliper, LH (Incl. 1-6,8,9)

Ref. Part No.

Ring, Molded Square, .103 x .134

BRAKE LINES, FRONT

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

MASTER CYLINDER, REAR and FOOT PEDAL

1 Kit, Brake Line, Rear

Ref. Part No.

CONTROLS - THROTTLE ASM./CABLE

E 2004 Polaris Sales Inc.

Ref. Part No.

DRIVE SHAFT, FRONT

E 2004 Polaris Sales Inc.