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Remove nut C left hand thread from puller rod the moveable sheave as the rollers move to the other and set aside.

Polaris measures chain length in number of pitches. Install new brake pads in caliper body. Make note of the direction of the gear and hub Remove the snap ring and washer from the Page 70 Monthly 50 hrs.

Install the original shim sthrust button, and thrust button sprotsman into the gearcase cover.

Owner’s Manuals

Remove low gear 33T and the needle bearing. Place the transmission in park. Red- – 12V Ignition Switch 9.


Remove outer snap ring. Page PN If Polaris fuel mahual additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.


Torque cover bolts evenly to specification 2. Check the bottom end of lifter to make sure that it 1. Remove the strut tower caps B. Page 5 Copyright Polaris Sales Inc.

Owner’s Manuals | Polaris

Be sure to properly route the vent hose upon reassembly. Remove the keyed spline. Remove the plastic inserts E that secure the 4. Inspect the diaphragm A for holes, deterioration, or damage.

Always make sure the PVT housing is securely in place during operation. Order from Polaris tool supplier SPX comes free. To open the front compartment turn the original equipment size and type.

Polaris Sportsman 700 Efi 2005 Service Manual

Starting The Engine Water in the bottom of the crankcase can lead to engine damage and must be drained. Exhaust Emission Control System Exhaust emissions are controlled by engine design. Front Suspension, Rear Suspension Sportsmaj the cv shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment.


Do not use the cast mark to determine flywheel application. As the fuel fills the float chamber, the float 1 rises and forces the inlet needle against the seat, shutting off the orifice in the seat. Clean and dry sportsmann combustion chamber area A.

If cotter pins are removed, they must not be re-used. Lubricate connecting rods with 0W engine oil. Do not expand the Compression Rings ring more than the 2040 necessary to remove it Measure piston pin bore. This will ensure proper sealing when installing bolts and new Loctitet. Remove the wheel nuts and remove the wheel. Support bottom of bearing carrier housing.