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Polaris Sportsman 800 twin Efi .pdf



Nom original: Polaris_Sportsman_800_twin_Efi_.pdf
Titre: 9917721

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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

5

3
4

6

E 2004 Polaris Sales Inc.

2
11

30

7

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
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.

11

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

18

3

5
6

12
7

8
15
9
10
11

12

17

13
14
16
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

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

3

33

1
32

4

35

3

31
30
29

31
6
2

5

1

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
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

2

3

4

5

6
7
3

1

E 2004 Polaris Sales Inc.
9
8
12
13

9

14
15

11

10

16

17
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
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

2

3
4

5

6

7

8

9
3
1
E 2004 Polaris Sales Inc.

10

12

14

13

15

11

17
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
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

E 2004 Polaris Sales Inc.

9
10
11

22

16

12

15

15
16

21

13
14

15

20
16
17

19

18

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

E 2004 Polaris Sales Inc.

16
5

17

7

6

1
10
2

3

9

9

4

18
19

8
7

20
21

23
24

22

38
7

27

26

9
7

25

28

37

24

29

35
11
34

7

33

32

30

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.

17
16

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

5

14
15

4

18

17

29

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


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