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This workshop repair service manual PDF download for the 2007 Polaris Sportsman 700/800/800 X2 EFI has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
2007 SPORTSMAN 700 EFI
MODEL NUMBER: A07MH68AX, AY, AZ
(Standard Model Only)
ENGINE MODEL: EH068OLE
2007 SPORTSMAN 800 EFI
MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA
(Standard) (Deluxe) (International)
ENGINE MODEL: EH076OLE
2007 SPORTSMAN X2 800 EFI
MODEL NUMBER: A07TH76AU, A07TN76AF
(Standard) (Deluxe)
ENGINE MODEL: EH076OLE
TABLE OF CONTENTS :
FOREWORD
CHAPTER INDEX
CH 1 – GENERAL INFORMATION
CH 2 – MAINTENANCE
CH 3 – ENGINE
CH 4 – FUEL INJECTION
CH 5 – BODY/STEERING/SUSPENSION
CH 6 – CLUTCH SYSTEM
CH 7 – FINAL DRIVE
CH 8 – TRANSMISSION / SPORTSMAN
CH 8 – TRANSMISSION / X2
CH 9 – BRAKES
CH 10 – ELECTRICAL
CH 11 – INTERNATIONAL
INDEX
WIRE DIAGRAMS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9920378
Total Pages : 393
This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
More Info : http://www.sitelux.com
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FOREWORD
understanding manual safety labels and directions
TRADEMARKS
CHAPTER INDEX
CH 1 – GENERAL INFORMATION
MODEL INFORMATION
Model Number/VIN Identification
Model Number
Engine Designation Numbers
VIN Identification
TRANSMISSION I.D. LOCATION
Engine and Machine Serial Numbers
PUBLICATIONS
Publication Numbers
PAINT CODES
Paint Codes
REPLACEMENT KEYS
Keys, Replacement
Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison
Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison
2007 SPORTSMAN 700 EFI
Specifications, Sportsman 700 EFI
MODEL NUMBER: A07MH68AX, AY, AZ
2007 SPORTSMAN 800 EFI
Specifications, Sportsman 800 EFI
MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA
2007 SPORTSMAN X2 800 EFI
Specifications, Sportsman 800 X2 EFI
MODEL NUMBER: A07TH76AU, A07TN76AF
Misc. Tables
MISC. NUMBERS/CHARTS
Standard Torque Specifications
Specification, Standard Fastener Torques
SPECIAL TOOLS
SAE Tap Drill Sizes
Specification, Drill and Tap Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Conversion Table
Conversion Table
Glossary Of Terms
Glossary of Terms
CH 2 – MAINTENANCE
MAINTENANCE
Maintenance Chart, Periodic
Overview
Periodic Maintenance Chart
LUBRICATION / FLUIDS
SPORTSMAN Component Locations
Component Locations, Sportsman
SPORTSMAN X2 Component Locations
Component Locations
Polaris Lubricants, Maintenance and Service Products
Lubricants/Fluids, Polaris Brand Part Numbers
Polaris Lubricant Symbol Identification
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
Pre-Ride / Daily Inspection
Pre-ride Checklist
Lubrication / Grease Points
Lubrication / Grease Points
Front Gearcase Lubrication
Front Gearcase Lubrication
Transmission Lubrication
ADC Differential Hydraulic Circuit Fluid Change
Gearcase, ADC Hydraulic Fluid Change
VEHICLE INSPECTION
Shift Link Rod Inspection
Shift Linkage Inspection
Throttle Inspection
Throttle Inspection
Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
Throttle Cable
Fuel System
Fuel Filter
Vent Lines
Vent Lines
Compression Test
Compression Test
Engine Mounts
Engine Mount
Spark Plug
Spark Plug
Active Descent Control (ADC) Reservoir Level
ADC reservoir level inspection
Battery Maintenance
Battery Maintenance
Cooling System
Cooling System
Coolant Strength / Type
Cooling Hoses
Cooling System Hoses
Radiator
Radiator
Cooling System Pressure Test
Cooling System – Pressure Test
Reservoir Level Inspection
Cooling System – Coolant Level
Radiator Coolant Level
Cooling System – Radiator Level
Air Filter Service
Air Filter Service
Air Box Sediment Tube
Air Box Sediment Tube
Engine Breather
Engine Breather Hoses
PVT Inspection / Drying Procedure
PVT Drying
Engine Ground
Engine Ground
Engine Oil Level
Engine Oil Level
Oil/filter Change
Engine Oil and Filter Change
Steering Inspection
Steering
Tie Rod / Steering
Tie Rod / Steering Inspection
Camber/Caster
Camber / Caster
Wheel Alignment
Wheel Alignment
Specification, Wheel Toe-Out
Toe Alignment
Exhaust Pipe
Exhaust Pipe
Brake System Inspection
Brake System Inspection
Brake Pads
Brake Pad Inspection
Brake Hose Inspection
Brake Hose Fitting Inspection
Auxiliary (Rear) Brake Test
Auxiliary (Rear) Brake Test
Auxiliary Brake Adjustment
Auxiliary Brake Adjustment
Suspension: Spring Preload Adjustment
Suspension Adjustment
Front Suspension
Suspension, Front
Rear Suspension
Suspension, Rear
CV Shaft Boot Inspection
CV Shaft Boot Inspection
ATV Controls
Wheel Inspection
Wheel Removal: Front Or Rear
Wheel Removal
Wheel Installation
Wheel Installation
Tire Pressure
Tire Inspection
Tire Inspection
Frame, Nuts, Bolts, Fasteners
Frame, Nuts, Bolts Fastener Inspection
Front / Rear Storage Compartments
Storage Compartments, Front & Rear
Winch Operation (If Equipped)
Warn Winch Operation
Cleaning And Storage Of ATV
Cleaning and Storage of ATV
Exhaust, 800 EFI
Maintenance Schedule
Maintenance Schedule
CH 3 – ENGINE
SPECIFICATIONS
Crankcase Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Exploded Views
Engine Fastener Torque Patterns
Engine Fastener Torques
Torque Specifications
Engine Torque Table
Torque Specs – Engine
700/800 EFI Engine Service Specifications
Engine Service Specifications
Special Tools
Special Tools, Engine
GENERAL ENGINE SERVICE
Accessible Components
Engine, Accessible Components
Piston Identification
Engine Piston Identification
Cooling System Specifications
Cooling System Specifications
Specifications, Cooling System
Engine Cooling System
Cooling System Pressure Test
Cooling System, Pressure Test
Engine Cooling System
Four Stroke – Coolant Air Bleeding Procedure
Cooling System Bleeding Procedure
Engine Removal (Typical)
Engine Removal / Install Procedure
Engine Installation Notes
Engine Installation Notes
Cylinder Hone Selection And Honing Procedure
Engine Cylinder Honing
Honing To Deglaze
Cylinder Honing To De-glaze
Cleaning the Cylinder After Honing
Oil Flow Chart
Engine Oil Flow Chart
Engine Lubrication Specifications
Specifications, Engine Lubrication
Engine Lubrication
OIL PRESSURE TEST
Engine Oil Pressure Test
Specifications, Engine Oil Pressure
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Cylinder Head Assembly Exploded View
Rocker Arms
Engine Rocker Arm Inspection
Push Rods
Engine Pushrod Inspection
Cylinder Head Removal
Engine Cylinder Head Removal
Cylinder Head Inspection
Engine Cylinder Head Inspection
Cylinder Head Warp
Engine Cylinder Head Warp
Specification, Cylinder Head Warp
Valve Seal/Spring Service (On Engine)
Valve Seal/Spring Service
Engine Valve Seal/Spring Service
Cylinder Head Disassembly
Cylinder Head Disassembly
Specification, Valve Spring Free Length
Valve Inspection
Engine Valve Inspection
Specification, Valve Stem Diameter
Specification, Valve Stem Guide I.D.
Combustion Chamber
Combustion Chamber
Valve Seat Reconditioning
Valve Seat Reconditioning
Engine Valve Seat Reconditioning
Specification, Valve Seat Contact Width
Cylinder Head Reassembly
Engine Cylinder Head Assembly
Cylinder Head Assembly
Valve Sealing Test
Engine Valve Sealing Test
Valve Sealing Test
Cylinder Removal
Engine Cylinder Removal
Valve Lifter Removal/Inspection
Engine Valve Lifter Removal, Inspection
Piston Removal
Engine Piston Removal, Inspection
Cylinder Inspection
Engine Cylinder Inspection
Cylinder Inspection
Specification, Cylinder Warp Limit
Specification, Cylinder Taper Limit
Piston-To-Cylinder Clearance
Piston to Cylinder Clearance
Engine Piston to Cylinder Clearance
Piston/rod Inspection
Engine Piston to Rod Clearance
Piston to Rod Inspection
Piston Ring Installed Gap
Piston Ring Installed Gap
Engine Piston Ring Installed Gap
Starter Drive/Bendix Removal Inspection
Starter Drive Removal
Engine Starter Drive Removal
Flywheel / Stator Removal / Inspection
Stator, Removal
Flywheel, Removal
Flywheel / Stator Removal
Engine Flywheel / Stator Removal
Engine Crankcase Disassembly / Inspection
Engine Flywheel Removal
Engine Starter Removal
Engine Gear(s) Removal
Specification, Timing Gear Alignment
Timing Gear Mark Alignment
Cam Gear, Removal
Cam Gear, Reassembly
Special Tool, Cam Gear Installation Kit
Balance Shaft Gear, Removal
Crankshaft Gear, Removal
Engine Crankshaft Gear Removal
Oil Pump, Removal
Engine Oil Pump Removal
Oil Pump, Disassembly
Specification, Oil Pump Rotor Clearance
Oil Pump, Reassembly
Engine Balance Shaft Removal
Camshaft Inspection
Engine Camshaft Inspection
Specification, Cam Lobe Height
Specifications, Cam Shaft
ENGINE REASSEMBLY
CRANKCASE REASSEMBLY
Engine Crankcase Assembly
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pick-up Bolt Torque
Engine Camshaft Installation
Engine Crankshaft Installation
Specifications, Crankcase Fastener Torque
Engine Cylinder Installation
Engine Piston Installation
Specification, Cam Thrust Plate Fastener Torque
Engine Oil Pump Installation
Specification, Oil Pump Bolt Torque
Engine Gears, Installation
Specification, Balance Shaft Gear Bolt Torque
Specification, Camshaft Gear Bolt Torque
Gear / Stator Housing Seal Replacement
Engine Stator Gear Cover Seal(s) Installation
Engine Stator Installation
Engine Oil Priming
Flywheel / Stator Installation
Engine Flywheel / Stator Installation
Cylinder Head Reassembly
Engine Head Assembly
TROUBLESHOOTING
Engine
Engine Troubleshooting
Cooling System
Engine Cooling System Troubleshooting
800 EFI Exhaust System (DELUXE)
Dual Exhaust Layout
Exhaust Breakdown, Sportsman 800 EFI
Exhaust, Dual 800 EFI
CH 4 – FUEL INJECTION
GENERAL INFORMATION
Special Tools
Fuel Injection, Special Tools
Service Notes
Fuel Injection, Service Notes
EFI System Exploded View
Fuel Injection, Exploded View
EFI System Component Locations
Fuel Injection, Component Locations
Fuel Tank Assembly
Fuel Tank Location
Fuel Lines – Quick Connect
ELECTRONIC FUEL INJECTION
Principal Components
EFI Operation Overview
EFI Operation Overview
Initial Priming / Starting Procedure
EFI Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
Electronic Control Unit (ECU)
ECU Service
ECU Replacement
FUEL PUMP
Operation Overview
Fuel Pump / Tank Assembly
Fuel Pump Test
Fuel Pump / Tank Assembly Replacement
FUEL PRESSURE REGULATOR
Operation Overview
Fuel Pressure Regulator
Fuel Pressure Regulator Test
Fuel Pressure Regulator Replacement
FUEL FILTERS
General Information
Fuel Filter
Fuel Filter Service
Fuel Filter Replacement
FUEL INJECTORS
Operation Overview
Fuel Injector
Fuel Injector Service
Fuel Injector Replacement
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview
Crankshaft Position Sensor (CPS)
Crankshaft Position Sensor Test
Crankshaft Position Sensor (CPS) Replacement
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
Operation Overview
Temperature / Barometric Air Pressure Sensor (T-Bap)
Temperature and Barometric Air Pressure Sensor Test
Temperature and Barometric Air Pressure Sensor Replacement
THROTTLE POSITION SENSOR (TPS)
Operation Overview
Throttle Position Sensor
Throttle Position Sensor Replacement
Throttle Position Sensor Replacement
Throttle Position Sensor Test
Throttle Position Sensor Initialization
Throttle Position Sensor Initialization
ENGINE TEMPERATURE SENSOR
Operation Overview
Engine Temperature Sensor
Engine Temperature Sensor Test
Engine Temperature Sensor Test
Engine Temperature Sensor Replacement
Engine Temperature Sensor Replacement
TROUBLESHOOTING
Diagnostics Using “Blink Codes”
Engine Diagnostic Codes
EFI Troubleshooting
EFI Troubleshooting
EFI CIRCUIT – Power On
Fuel System, EFI Circuit Diagrams
Troubleshooting, EFI Circuit Diagrams
EFI CIRCUIT – Crank Position Sensor
EFI CIRCUIT – Fuel Pump
EFI CIRCUIT – Throttle Position Sensor
EFI CIRCUIT – Temperature – Barometric Air Pressure Sensor
EFI CIRCUIT – Engine Temperature
EFI CIRCUIT – Malfunction Indicator Light
CH 5 – BODY/STEERING/SUSPENSION
GENERAL INFORMATION
Torque Specifications
Specifications, Body and Steering Torque Values
Body and Steering Torque Values
Steering Torque Values
Special Tools
Special Tools, Body & Steering
Decal Replacement
Decal Replacement
Plastic Insert Removal / Installation
Plastic Inserts
BODY
Side Panel Removal
Side Panel Removal
Front Cover Removal / Installation
Front Cover Removal / Installation
Foot Well Removal / Installation
Foot Well Removal / Installation
X2 Foot Well Removal / Installation
Foot Well Removal / Installation
Front Storage Removal
Front Storage Removal
Front Storage Installation
Front Storage Installation
Sportsman Rear Rack Removal / Installation
Rear Rack Removal / Installation
Front Cab/Fender Removal/Installation
Front Cab Removal / Installation
Sportsman Rear Cab / Fender Removal / Installation
Rear Cab Removal / Installation
X2 Rear Quarter Panel Removal / Installation
Sportsman Rear Storage Removal / Installation
Rear Storage Removal / Installation
Radiator Screen Removal
Radiator Screen Removal
Sportsman Body Assembly Exploded View
Body Assembly Exploded View
X2 Body Assembly Exploded View
Body Assembly Exploded View
Body / Rack Exploded Views
Body Rack Exploded View
Headlight Pod Exploded View
Headlight Pod Exploded View
STEERING
Handlebar Block Installation Procedure
Handlebar Block Installation Procedure
Steering / A-arm Exploded View
Steering A-Arm Exploded View
A-Arm Replacement
A-Arm Replacement
Ball Joint Replacement
Ball Joint Replacement, Front
Steering Post Removal
Steering Post Removal
Steering Post Assembly
Steering Post Assembly
SUSPENSION
Front Strut Cartridge Replacement
Strut Cartridge Replacement, Front
Strut Assembly
Strut Assembly
Sportsman Rear Suspension Assembly
Rear Suspension Assembly
X2 Rear Suspension Exploded View
Rear Suspension Assembly
X2 Torsion Bar Exploded View
X2 CARGO BOX
Exploded View
Removal / Installation
Cargo Box, Removal and Installation
X2 SEAT assembly
Exploded Views
X2 Seat Operation – Configuring Cargo Box For Passenger Riding
Passenger Seat, Operation
Driver Seat Backrest Removal / Installation
X2, Seat Disassembly
Passenger Seat Backrest Removal / Installation
CH 6 – CLUTCH SYSTEM
SPECIAL TOOLS AND SPECIFICATIONS
Special Tools
PVT Special Tools
Component Fastener Torques
PVT Torque Specs
Specification, PVT Component Torque Table
PVT EXPLODED VIEWS
PVT Sealing And Ducting Components
PVT Ducting
Drive Clutch Exploded Views (Standard and Deluxe)
PVT, Drive Clutch Exploded View
Driven Clutch Exploded Views (Standard and Deluxe)
EBS Exploded View
Engine Braking System (EBS) Exploded View
EBS Exploded View
PVT SYSTEM
PVT Operation Overview
PVT Operation
Drive Clutch Operation
PVT Drive Clutch Operation
Drive Clutch, Operation
Driven Clutch Operation
PVT Driven Clutch Operation
Driven Clutch, Operation
EBS Clutch Operation
PVT, EBS Clutch Operation
EBS, Driven Clutch Operation
PVT Maintenance / Inspection
PVT Maintenance / Inspection
Drive Clutch Spring
PVT Drive Clutch Specifications
Drive Clutch Springs
Optional Shift Weights
PVT Drive Clutch Shift Weights
Drive Clutch Weights
PVT Drying
PVT Drying
PVT Disassembly
PVT Disassembly
PVT Installation
PVT Assembly
Drive Belt Removal / Inspection
PVT, Drive Belt Removal/Inspection
Drive Belt, Removal/Inspection
Specification, PVT Drive Belt Width
Specification, PVT Center-to-Center Distance
DRIVE BELT INSTALLATION
PVT, Drive Belt Installation
Drive Belt, Installation
Clutch Alignment
PVT, Clutch Alignment
Clutch Alignment
Clutch Offset
PVT, Clutch Offset
Clutch Offset
EBS DRIVE CLUTCH SERVICE
EBS Drive Clutch Service
Drive Clutch Disassembly
PVT, Drive Clutch Disassembly
Spider Removal
PVT, Drive Clutch Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
PVT, Button to Tower Clearance
Drive Clutch Inspection
Moveable Sheave Bushing Inspection
PVT, Moveable Sheave Inspection
Drive Clutch Bushing Service
PVT, EBS Drive Clutch Bushing Service
PVT, EBS Drive Clutch Cover Bushing Remove/Install
One-Way Clutch Inspection (Drive Clutch)
Drive Clutch Reassembly
PVT, Drive Clutch Reassembly
EBS DRIVEN CLUTCH SERVICE
EBS Driven Clutch Service
Driven Clutch Disassembly
PVT, Driven Clutch Disassembly
DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION
PVT, Driven Clutch Bushing Service
EBS DRIVEN CLUTCH REASSEMBLY
PVT, Driven Clutch Reassembly
standard drive clutch
Drive Clutch, Standard Service
Drive Clutch Disassembly
PVT, Drive Clutch Disassembly
Spider Removal
PVT, Drive Clutch Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
PVT, Button to Tower Clearance
Sheave / Bushing Inspection
PVT, Moveable Sheave Inspection
Drive Clutch Bushing Service
PVT, EBS Drive Clutch Bushing Service
PVT, EBS Drive Clutch Cover Bushing Remove/Install
Drive Clutch Reassembly
PVT, Drive Clutch Reassembly
standard driven clutch
Driven Clutch, Standard Service
Disassembly
Inspection
Assembly
PVT TROUBLESHOOTING
Clutch, Troubleshooting
Overheating
PVT Overheating Chart
Problem, Cause and Remedy Chart
PVT Troubleshooting Chart
CH 7 – FINAL DRIVE
SPECIFICATIONS
Torque Table
Specifications, Final Drive Torque Values
Final Drive Torque Specifications
Special Tools
Special Tools, Final Drive
Gearcase Fluid / Capacity
Specifications, Front Gearcase Lubrication Type/Capacity
Gearcase, Front Capacity and Fluid Type
FRONT DRIVE AXLE
Removal
Front Drive Axle Removal
Installation
Front Drive Axle Installation
FRONT DRIVE SHAFT (CV) BOOT
Inspection
Drive Shaft Boot Inspection
Replacement
CV Boot, Replacement
FRONT HUB
Disassembly
Front Hub, Disassembly
Assembly
Front Hub, Assembly
PROP SHAFT – FRONT OR REAR
Removal and Installation
Propshaft, Removal
U-JOINT
U-joint, Disassembly and Assembly
Disassembly
Assembly
DRIVE AXLE EXPLODED VIEWS
Drive Shafts and Propshafts
FRONT GEARCASE – CENTRALIZED HILLIARD (STANDARD MoDELS)
Front Gearcase, Operation
Exploded View (Standard Models)
Front Gearcase, Exploded View
Operation
Gearcase Removal
Front Gearcase, Removal
Disassembly / Inspection
Front Gearcase, Disassembly / Inspection
Front Gearcase Coil Resistance
Reassembly / Inspection
Front Gearcase, Reassembly / Inspection
Front Gearcase – Back Lash Pad Adjustment
Setting Ring Gear Backlash
Front Gearcase Diagnosis
Front Gearcase, Diagnoses
Gearcase Installation
Front Gearcase, Installation
FRONT GEARCASE – Active descent control (deluxe models)
ADC Gearcase Exploded View (Deluxe Models)
Front Gearcase, Active Descent Control Exploded View
Operation
Active Descent Control Gearcase
ADC Coil Testing
ADC Differential Hydraulic Circuit Bleeding
Disassembly / Inspection
ADC Gearcase, Disassembly / Inspection
Front Gearcase Coil Resistance
ADC Gearcase Piston Replacement Procedure
ADC Gearcase Piston Service
Assembly
Front Gearcase, Reassembly
REAR HUB
Removal
Disassembly
Assembly
Installation
REAR DRIVE (CV) SHAFT
Removal
Service
CV Boot Replacement
INSTALLATION
Drive Shaft and CV Joint Handling Tips
REAR GEARCASE
Removal
Rear Gearcase, Removal
Disassembly and Inspection
Rear Gearcase, Disassembly
Reassembly
Rear Gearcase, Assembly
Installation
Rear Gearcase, Installation
Rear Gearcase Exploded View
Rear Gearcase, Exploded View
sPORTSMAN 8.3-8.18
sPORTSMAN X2 8.19-8.38
CH 8 – TRANSMISSION / SPORTSMAN
TRANSMISSION EXPLODED VIEW
Sportsman Transmission
Transmission Exploded View
SPECIFICIATONS
Torque Specifications
Lubricant / Capacity
TRANSMISSION SERVICE
Transmission Removal
Transmission Gear Selector Removal
Transmission Removal
Disassembly
Transmission Disassembly
Assembly
Transmission Assembly
Transmission Installation
Transmission Installation
Troubleshooting
Transmission Troubleshooting
CH 8 – TRANSMISSION / X2
Transmission
TRANSMISSION EXPLODED VIEWS
X2 Transmission Exploded View
Transmission, Exploded View
X2 Mounting Exploded View
Transmission Mounts, Exploded View
sPECIFICATIONS
Torque Specifications
Special Tools
Transmission, Special Tools
Lubrication
TRANSMISSION SERVICE
Gear Selector Removal
Transmission Removal
Transmission, Removal
Transmission Installation
Transmission, Install
Troubleshooting Checklist
Transmission Disassembly
Transmission, Disassembly
Transmission assembly
Transmission, Reassembly
Transmission front output shaft backlash procedure
Transmission, Output Shaft Backlash Procedure
Specification, Transmission Silent Chain Length
CH 9 – BRAKES
SPECIFICATIONS
Torque Table
Brake, Torque Specifications
Specifications, Brake Component Torque Values
Component Service Limits
Specifications, Brake Component Service Limits
BRAKE SYSTEM Exploded Views
Brake System Exploded Views
X2 System Component Exploded View
Brake System Components, X2
Sportsman System Component Exploded View
Brake System Components, Std, Sportsman
BRAKE CALIPER EXPLODED VIEWS
Brake Caliper Exploded View
Sportsman and X2 Front Caliper Assembly
X2 Rear Caliper Assembly
Sportsman Rear Caliper Assembly
HYDRAULIC BRAKE SYSTEM
Hydraulic Brake System Operation Overview
Operation Overview
Brakes, Operation Overview
Brake Noise Troubleshooting
Brake Noise Troubleshooting
Brake Bleeding / Fluid Change
Brake Bleeding
FRONT MASTER CYLINDER
Brake, Master Cylinder Removal
Removal
Installation
FRONT BRAKES
Brake Pad, Removal and Installation
Pad Removal
Assembly
Brake Burnishing Procedure
Brake Burnishing Procedure
FRONT BRAKE DISC
Brake Disc, Front
Inspection
Removal / Replacement
FRONT CALIPER
Brake Caliper, Front
Removal
Inspection
Reassembly
Installation
REAR BRAKE PAD
Brake Pad, Rear
X2 Pad Removal
X2 Pad Installation
Sportsman Rear Pad Removal
Brake Pad Removal, Rear
Specification, Brake Pad Thickness
Sportsman Rear Pad Installation
Brake Pad Install, Rear
Brake Burnishing Procedure
X2 REAR CALIPER
Brake Caliper Removal, Rear
Removal
Inspection
Reassembly
Sportsman REAR CALIPER
Removal and Inspection
Brake Caliper Removal, Rear
Assembly
Brake Caliper, Assembly
REAR BRAKE DISC
Brake Disc, Inspection
Inspection
Specification, Brake Disc Thickness
Specification, Brake Disc Service Limit
REAR MASTER CYLINDER
Brake, Rear Auxiliary Master Cylinder
X2 Exploded View
Rear Master Cylinder, Exploded View
Overview
X2 Rear Master Cylinder Removal and Installation
Sportsman Rear Master Cylinder Removal / Installation
Brake, Rear Auxiliary Brake
Pedal Removal and Installation
TROUBLESHOOTING
Brakes, Troubleshooting
Brakes Squeal
Poor Brake Performance
Lever Vibration
Caliper Overheats (Brakes Drag)
Brakes Lock
CH 10 – ELECTRICAL
INSTRUMENT CLUSTER
Instrument Cluster (Speedometer) Overview
Overview
Speedometer, Funtions Overview
Instrument Cluster Diagnostic Mode
Diagnostic Mode, Instrument Cluster
Clock, Setting Time of Day
Setting A New Service Interval
Instrument Cluster, Setting New Service Interval
Service Intervals, Speedometer
EFI Diagnostic Mode
EFI Diagnostic Mode Using Instrument Cluster
Diagnostic Mode, EFI System
Diagnostic Codes
Speedometer Removal
Speedometer Removal
Speedometer Installation
Speedometer Installation
SPEEDOMETER TROUBLESHOOTING
Test 1 – No All Wheel Drive
Speedometer Troubleshooting Tests
TEST 2 – No Display / TEST 3 – No Reverse Speed Limit
TEST 4 – No AWD Hub Safety Limiter
TEST 5 – Reverse Speed Limiter / TEST 6 – Speed Sensor
TEST 7 – No Fuel Gauge / TEST 8 – Transmission Switch
ACTIVE DESCENT CONTROL (ADC) COIL
Active Descent Control (ADC) Coil
Operation Overview
Diagnosing System Failures
ALL WHEEL DRIVE (AWD) COIL
All Wheel Drive (AWD) Coil
Operation Overview
Diagnosing System Failures
COOLING SYSTEM COMPONENTS
Fan Control Circuit Operation / Testing
Fan Control Circuit Operation
Fan Control Circuit Bypass Test
Fan Control Circuit Operation / Testing
Coolant Temperature Sensor
Specification, Coolant Sensor Resistance
Fan Motor Current Draw
Fan Motor Current Draw
GEAR POSITION INDICATOR SWITCH
Test Diagram
Gear Position Indicator Switch Test
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
ETC Switch Operation
ETC Switch Operation
ETC Operation Test
ETC Operation Test
IGNITION SYSTEM
Flywheel Identification
Flywheel ID
EFI – DC/CDI Ignition Overview
Ignition Curve
Alternator/Ignition Components – 700/800 EFI
Alternator / Ignition Components
Crankshaft Position Sensor Gap
Crank Position Sensor Gap
Ignition System Troubleshooting
Ignition System Troubleshooting
CHARGING SYSTEM
Current Draw – Key Off
Current Draw – Key Off Test
Charging System “Break Even” Test
Charging System – Break Even Test
Alternator Output Test
Alternator Output Test
Charging System Testing Flow Chart
Charging System Flow Chart
RELAYS
Operation
Relays
FUSES/Circuit Breaker
Operation
Fuses
Circuit Breaker
LIGHTING
High Beam Headlight Bulb Replacement
High Beam Bulb Replacement
Headlight Housing Replacement
Headlight Housing Replacement
High Beam Headlight Adjustment
High Beam Headlight Adjustment
Lower Headlamp Removal / Installation
Lower Headlamp Removal
Lower Headlamp Housing Removal
Low Beam Headlight Adjustment
Low Beam Headlight Adjustment
Headlamp Switch Test
Headlamp Switch Test
Sportsman Work Light Switch (Deluxe)
Work Light Switch
Sportsman Brake Light / Work Light (Deluxe) Replacement
Brake Light / Work Light Switch Replacement
X2 BRAKE LIGHT / WORK LIGHT (Deluxe) REPLACEMENT
Brake Light / Work Light Switch Replacement
Brake Light Switch
Brake Light Switch
FUEL SENDER
Testing
Fuel Sender Test
X2 DIFFERENTIAL System
Solenoid Testing
Solenoid, Differential
Differential Solenoid
Specification, Differential Solenoid Resistance
Solenoid Replacement
Specification, Differential Solenoid Torque
Differential Relay Operation
Differential Relay Testing
X2 SPEED SENSOR
Testing
Speed Sensor
Special Tools, Speed Sensor
Specification, Speed Sensor Bolt Torque
Specification, Differential Solenoid Resistance
Replacement
Speedometer Sensor, Replacement
Specification, Differential Solenoid Torque
ACCESSORY POWER
Wire Connections
Accessory Power Wiring
STARTER SYSTEM
700/800 Starter Lockout Overview and Diagnostic
Starter Interlock
Interlock, Starter, 700/800 EFI
800 X2 Starter Lockout Overview and Diagnostic
Starter Interlock
Interlock, Starter, 800 X2 EFI
Troubleshooting
Starter System, Troubleshooting
Voltage Drop Test
Voltage Drop Test
Starter Motor Removal / Disassembly
Starter Motor, Removal
BRUSH INSPECTION / REPLACEMENT
Starter Brush Inspection / Replacement
Armature Testing
Starter Armature Testing
Starter Reassembly / Installation
Starter Reassembly / Installation
Starter Solenoid Bench Test
Starter Drive
Starter Drive
Starter Exploded View
Starter Assembly Exploded View
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test
Starter System Flow Chart
BASIC WINCH WIRING- PRE-WIRED MODELS
Winch, Basic Wiring Diagram
BATTERY
Battery Identification
Battery Activation (Conventional)
Battery Activation, Conventional
Battery Terminals/Bolts
Battery Terminals/Bolts
Conventional Battery Inspection / Removal
Battery Removal / Inspection, Conventional
Conventional Battery Installation
Conventional Battery Testing
Conventional Battery OCV – Open Circuit Voltage Test
Conventional Battery Specific Gravity Test
Specific Gravity Test, Conventional Battery
Battery Load Test
Battery Load Test
Off Season Storage
Battery Off Season Storage
Charging Procedure
Charging Procedure
Low Maintenance Battery
Low Maintenance Battery Info
Low Maintenance Battery Charging
Low Maintenance Battery Charging
Low Maintenance Battery Inspection / Removal
Battery Inspection / Removal, Low Maintenance
Low Maintenance Battery Installation
Battery Installation, Low Maintenance
Low Maintenance Battery – OCV- Open Circuit Voltage Test
Battery Open Circuit Voltage (OCV), Low Maintenance
Low Maintenance Battery Load Test
Battery Load Test, Low Maintenance
Low Maintenance Battery Off-season Storage
Battery Off Season Storage, Low Maintenance
Low Maintenance Battery Charging Procedure
Battery Charging Procedure, Low Maintenance
CH 11 – INTERNATIONAL
800 EFI International BRAKE SYSTEM
Brake System Overview, International
Overview
Exploded View
Brake System Exploded View, International
800 EFI International Steering Post and lock Assembly
Steering Lock, Exploded View
Steering Assembly Exploded View
800 EFI INTERNATIONAL ELECTRICAL
Turn / Hazard Signal Diagram
INDEX
WIRE DIAGRAMS
–
Polaris Sportsman 700/800/800 X2 EFI Repair Service Manual 2007.pdf
Source : Sitelux.com
