2005 Polaris Sportsman 800 EFI Parts Manual - PDF DOWNLOAD

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

A--ARM . . . . . . . . . . . . . . . . . . . . . . . . . C7 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . B3

B

BRAKE LINES, FRONT . . . . . . . . . . . . . B7 BRAKE, FRONT . . . . . . . . . . . . . . . . . . . B6 BUMPER MOUNTING . . . . . . . . . . . . . . . A7-8

C

CAB, FRONT . . . . . . . . . . . . . . . . . . . . .

CAB, REAR . . . . . . . . . . . . . . . . . . . . . .

CALIPER, REAR . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . .

CONTROLS . . . . . . . . . . . . . . . . . . . . . .

CONTROLS -- THROTTLE ASM./CABLE .

COOLING SYSTEM . . . . . . . . . . . . . . . .

CRANKCASE . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT . . . . . . . . . . . . . . . . . . . .

CYLINDER . . . . . . . . . . . . . . . . . . . . . . .

D

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

E

F

FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . B9 FUEL INJECTOR . . . . . . . . . . . . . . . . . . E5 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . B4

G

H

I

INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . E2

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . E6 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . D13 MASTER CYLINDER, REAR . . . . . . . . . . B9

O

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . E3 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . E4

P

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . D14 PROP SHAFT, FRONT . . . . . . . . . . . . . . B13 PROP SHAFT, REAR . . . . . . . . . . . . . . . B14

R

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . D3--4 ENGINE MOUNTING . . . . . . . . . . . . . . . . B1-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . A12

GEAR SELECTOR . . . . . . . . . . . . . . . . .

GEARCASE . . . . . . . . . . . . . . . . . . . . . .

GEARCASE MOUNTING, REAR . . . . . . .

GEARCASE, REAR . . . . . . . . . . . . . . . . .

H

HEADLIGHT POD . . . . . . . . . . . . . . . . . . C1--2 HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . C6 HOUSING, FRONT . . . . . . . . . . . . . . . . . D6

C9 D7-8 D10 D9

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . C1-2

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

S

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING MOTOR . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . .

STORAGE BOX, REAR . . . . . . . . . . . . .

STORAGE, FRONT . . . . . . . . . . . . . . . . .

STORAGE, FRONT . . . . . . . . . . . . . . . .

STRUT MOUNTING . . . . . . . . . . . . . . . .

STRUT, FRONT . . . . . . . . . . . . . . . . . . .

SUSPENSION, REAR . . . . . . . . . . . . . . .

T

TAILLAMPS . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT . . . . . . . . . . . . . . . . . . . .

THROTTLE BODY MOUNTING . . . . . . . .

TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION MOUNTING . . . . . . . . .

W

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 1

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CAB, REAR and SEAT SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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

1

5436108-177

1

5435363-070

1

5436108-070

1

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 5

E 2004 Polaris Sales Inc.

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2 4

3

10

12 11

5 6

7 9

7 8

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 1 19

2 4

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12 7

8 15 9 10 11

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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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

34 E 2004 Polaris Sales Inc. 2

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10 21 12 13

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A7

STORAGE, FRONT and BUMPER MOUNTING SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc.

2

3

7

4

8

5 6

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

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

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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

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

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3 4

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9 3 1 E 2004 Polaris Sales Inc.

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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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

6

8

5

4

1 2 3 4

1 2 3

5

28

26

27 7 8

25

7

23

24

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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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 11 12

14 15

13

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17

7

6

1 10 2

3

9

9

4

18 19

8 7

20 21

23 24

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38 7

27

26

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25

28

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24

29

35 11 34

7

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36 31

A13

COOLING SYSTEM SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

18

19

E 2004 Polaris Sales Inc.

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20 1

15 14 8

3 5

2 5

4

13

2

6

7

12

8

9

B1

10

11

ENGINE MOUNTING SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

6

E 2004 Polaris Sales Inc.

1

2 3

5

7

8

4

9

31 30 10

29

11

28 27

19

12

18

13 17

26

25 24 23

22 21 20

16

15

14

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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

9 8

10

E 2004 Polaris Sales Inc. 7 6 1 2

3 4

5

15 12

13

14 11

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 E 2004 Polaris Sales Inc. 2

3

4 6

5

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

2

3 E 2004 Polaris Sales Inc.

10

4

5 6

7

9

8

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

1 2 3 4

3

10 9 8

5 6 2

7 2

1

1

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

2

E 2004 Polaris Sales Inc.

3

4, 5 3

5 3 4, 5 6 7

1, 3

1 1, 3, 7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

3

8

4

10

9

15

2

11 E 2004 Polaris Sales Inc.

1 2

14

12

5

6

16

13

4 7

17

18

19 20

21

22

22 23

23

25

14

26

24

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 1

2 3

5 4

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

2

3

4

5

1

3 6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 1

2

3

4

4

5

10

6

2

7

8

9

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc. 3

2 4

5

6

7

3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

2

3

1

1

4

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

1

2

29

6 30 31

3

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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

1

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

5

1 2

6

3

E 2004 Polaris Sales Inc. 16

7

22

4

8 21

17

11

20

19

18

9

16

11

13

14

15 11 10 12

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 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 SPORTSMAN 800 EFI A05MH76AC

8

9

7 6

E 2004 Polaris Sales Inc. 4 2

5

3 10

1

12

11

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

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 SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

7

8

6 5 E 2004 Polaris Sales Inc. 4

3

9

1 10

2

11

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 1 8

10

7 9

2

6

5

4 3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

24

1 2

E 2004 Polaris Sales Inc. 25

26

28

3 4

26 28

5

25

24

23

27 22

6 7

21 8 9

10

18

11

19

20

17 12 8

15

13

16

14

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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

2 1

3 10 3 4

E 2004 Polaris Sales Inc.

5 6

7

1

5 10

8

9

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

4 1

E 2004 Polaris Sales Inc. 2

3 5 11 10

4

9

8

6

7

5

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

5 E 2004 Polaris Sales Inc. 1

4 2

6 7

3

8

2 10 5

13 12 14

9

11

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

13

14

1

12 11

2

3

10

15

4 5

16 17

9 18

E 2004 Polaris Sales Inc. 19

20

8

21

7 6

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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

7 5

8

6

9

4 E 2004 Polaris Sales Inc.

8 3 10

1

2

12

11

13 14 15

16

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

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 SPORTSMAN 800 EFI A05MH76AC

11 10 9

E 2004 Polaris Sales Inc. 8 7 5

12 6

4

13

3

2

1

15

14

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

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 SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

11 10 9

E 2004 Polaris Sales Inc. 7

8 12

5 4

3

1

6 13

2

14

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

3

E 2004 Polaris Sales Inc.

4

2 18 1 7 8

5

4

3

36 38

6

18 37

2

9 8

29

34

28

37

25

18

25

31 33

18

36

26

23

35

10

27

31

8

22 28

9

32

21

30

20 29

8 7 11 12

19 13 14

15

18

16

17

D1

24

SUSPENSION, REAR SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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 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

1

5245140-067 7552603 7512492 7555832 5434551 1014174-067 1014175-067 1014174-293

1 4 4 2 4 1 1 1

1014175-293

1

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

6

9

E 2004 Polaris Sales Inc. 10

24

25

8 20

12 7

23

21 22 11

6

13

6

19

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14 15

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18

17

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16 32 33

28

27

26

31 30

33

3 36

2

35

1 34 37

D3

39 38

ELECTRICAL SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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 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 Fuse, Self Resetting, 15 Amp Fuse, Self Resetting, 6 Amp Screw Cable Tie Clip, Rosebud Mount, Cable Tie Cable Tie Regulator, Volt Bracket, Voltage Regulator 10/04

D4

TRANSMISSION MOUNTING SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 9

12

1

3

2

1

5

10

5

11

3 4

8

9

6

5 5 7

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 2

E 2004 Polaris Sales Inc. 3 4

16

13

5

7

6 15

2

28

8

14 15

12

9

27

11

5

16

10 26

25

20

19

18

17

21

4 24

22 23

15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

19

18 16

E 2004 Polaris Sales Inc.

17 20

15 21

14 13

12

26 22

25

23

27 26 24

10

1

2

5

3

25

11

8 4

2

9

7

28

6

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc.

2

3

8

4

5

17 16

15

6

14 13

12

11

7

8

10

9

7

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc.

2 1

6

3 4 6 2

6

5

4

2

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 2

3

33

4

28 5

26

6

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

E 2004 Polaris Sales Inc.

CRANKCASE and CRANKSHAFT SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW 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 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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

1

2 3

4 5

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc.

2 10

3 9

4

5

5 6

4

7

8

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

2 3

4 5 6

14 7 E 2004 Polaris Sales Inc.

8 9 10 11 13 12

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1

E 2004 Polaris Sales Inc. 2

3 4 5 6

7 10 9 8

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 3

2

4 5 6

12

7 8

E 2004 Polaris Sales Inc.

11

10 9

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 2 3

4 E 2004 Polaris Sales Inc.

5 6 7

8

9 10

11

12

13

14 15

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc.

2

1

3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

2

3

1

E 2004 Polaris Sales Inc. 4 5 15

14 7

6

8 13

9

12

10

11

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

E 2004 Polaris Sales Inc. 3 1

2

4

7 6

5

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

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 SPORTSMAN 800 EFI A05MH76AC and SPORTSMAN 800 EFI A05MH76AU and SPORTSMAN 800 EFI A05MH76AW

1 E 2004 Polaris Sales Inc. 2

9 3

4

5

8 6

7

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

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 Owner’s Manual, ‘05 Sportsman 800 EFI 10/04

PRINTED IN THE USA

PARTS MANUAL PN 9917721 and MICROFICHE PN 9917722 10/04

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cover

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Changed pages in 9917721

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