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2007 POLARIS SPORTSMAN 700 800 800 X2 EFI ( 700 & 800 TWIN MODELS ) SERVICE | REPAIR | SHOP MANUAL #❶ 07 - DOWNLOAD

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(ID 89701720)
2007 POLARIS SPORTSMAN 700 / 800 / 800 X2 EFI ( 700 & 800 TWIN MODELS ) SERVICE MANUAL * DIY (DO-IT-YOURSELF) FACTORY SERVICE / REPAIR / SHOP MANUAL 07 - DOWNLOAD NOW !!

( VERY HIGH QUALITY FACTORY SERVICE MANUAL - MASSIVE CONTENTS - DOWNLOAD !! )

File Format: PDF
Compatible: All Versions of Windows & Mac
Downloadable:YES
Language: English
Requirements: Adobe PDF Reader

SERVICE MANUAL COVERS:
==================

GENERAL 1
MAINTENENCE 2
ENGINE 3
FUEL SYSTEM 4
BODY / SUSPENSION 5
CLUTCH 6
TRANSMISSION 7
FINAL DRIVE 8
BRAKES 9
ELECTRICAL 10
INTERNATIONAL 11

DETAILED INDEX:
=============

A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Accessory Power Wiring . . . . . . . . . . . . . . . . . . . . . . . 10.35
Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.15
Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.22
ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.27
ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.23
ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.17
Air Box Sediment Tube . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.15
Alternator / Ignition Components . . . . . . . . . . . . . . . . . 10.20
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Auxiliary (Rear) Brake Test . . . . . . . . . . . . . . . . . . . . . . 2.27
Auxiliary Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . 2.28
B
Balance Shaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . 3.38
Ball Joint Replacement, Front . . . . . . . . . . . . . . . . . . . . 5.19
Battery Activation, Conventional . . . . . . . . . . . . . . . . . 10.46
Battery Charging Procedure, Low Maintenance . . . . . 10.53
Battery Inspection / Removal, Low Maintenance . . . . 10.51
Battery Installation, Low Maintenance . . . . . . . . . . . . 10.51
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
Battery Load Test, Low Maintenance . . . . . . . . . . . . . 10.52
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Battery Off Season Storage . . . . . . . . . . . . . . . . . . . . . 10.49
Battery Off Season Storage, Low Maintenance . . . . . . 10.53
Battery Open Circuit Voltage (OCV), Low Maintenance . . .
10.52
Battery Removal / Inspection, Conventional . . . . . . . . 10.47
Battery Terminals/Bolts . . . . . . . . . . . . . . . . . . . . . . . . 10.47
Body and Steering Torque Values . . . . . . . . . . . . . . . . . . 5.2
Body Assembly Exploded View . . . . . . . . . . . . . . 5.12, 5.13
Body Rack Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.14
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Burnishing Procedure . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Caliper Exploded View . . . . . . . . . . . . . . . . . . . . . 9.5
Brake Caliper Removal, Rear . . . . . . . . . . . . . . . . 9.21, 9.23
Brake Caliper, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9.24
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Disc, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Brake Hose Fitting Inspection . . . . . . . . . . . . . . . . . . . . 2.27
Brake Light / Work Light Switch Replacement 10.30, 10.31
Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Brake Pad Install, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Brake Pad Removal, Rear . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Brake Pad, Removal and Installation . . . . . . . . . . . . . . . 9.10
Brake System Components, Std, Sportsman . . . . . . . . . . 9.4
Brake System Components, X2 . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Exploded View, International . . . . . . . . . 11.3
Brake System Exploded Views . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.26
Brake System Overview, International . . . . . . . . . . . . . .11.2
Brake, Master Cylinder Removal . . . . . . . . . . . . . . . . . . .9.9
Brake, Rear Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . .9.28
Brake, Rear Auxiliary Master Cylinder . . . . . . . . . . . . .9.26
Brake, Torque Specifications . . . . . . . . . . . . . . . . . . . . . .9.2
Brakes, Operation Overview . . . . . . . . . . . . . . . . . . . . . . .9.6
Brakes, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .9.29
C
Cam Gear, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
Cam Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
Camber / Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
Cargo Box, Removal and Installation . . . . . . . . . . . . . . .5.26
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.49
Charging System - Break Even Test . . . . . . . . . . . . . . .10.22
Charging System Flow Chart . . . . . . . . . . . . . . . . . . . .10.24
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.26
Cleaning and Storage of ATV . . . . . . . . . . . . . . . . . . . . .2.33
Clock, Setting Time of Day . . . . . . . . . . . . . . . . . . . . . . .10.4
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6.36
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
Component Locations, Sportsman . . . . . . . . . . . . . . . . . .2.7
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
Cooling System - Coolant Level . . . . . . . . . . . . . . . . . . .2.19
Cooling System - Pressure Test . . . . . . . . . . . . . . . . . . .2.19
Cooling System - Radiator Level . . . . . . . . . . . . . . . . . .2.20
Cooling System Bleeding Procedure . . . . . . . . . . . . . . . .3.15
Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
Cooling System Specifications . . . . . . . . . . . . . . . . . . . .3.14
Cooling System, Pressure Test . . . . . . . . . . . . . . . . . . . .3.15
Crank Position Sensor Gap . . . . . . . . . . . . . . . . . . . . . .10.21
Crankshaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . . .3.38
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . .4.14
Current Draw - Key Off Test . . . . . . . . . . . . . . . . . . . .10.21
CV Boot, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.28
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . .3.28
Cylinder Head Assembly Exploded View . . . . . . . . . . .3.21
Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . .3.24
Cylinder Honing To De-glaze . . . . . . . . . . . . . . . . . . . . .3.19
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
D
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
Diagnostic Mode, EFI System . . . . . . . . . . . . . . . . . . . .10.7
Diagnostic Mode, Instrument Cluster . . . . . . . . . . . . . . .10.4
Differential Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
Drive Belt, Removal/Inspection . . . . . . . . . . . . . . . . . . .6.12
Drive Clutch Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
IX.2
Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Drive Clutch, Standard Service . . . . . . . . . . . . . . . . . . . .6.28
Drive Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . .7.4
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Driven Clutch, Standard Service . . . . . . . . . . . . . . . . . . .6.34
E
EBS Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . .6.15
EBS Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . .6.22
EBS Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 6.4, 6.5
EBS, Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . .6.7
EFI Diagnostic Mode Using Instrument Cluster . . . . . . .10.7
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . .4.7
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . . .4.7
EFI Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . .4.8
Engine Balance Shaft Removal . . . . . . . . . . . . . . . . . . . .3.42
Engine Breather Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
Engine Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . .3.42
Engine Camshaft Installation . . . . . . . . . . . . . . . . . . . . .3.44
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 3.14, 3.15
Engine Cooling System Troubleshooting . . . . . . . . . . . .3.58
Engine Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . .3.43
Engine Crankshaft Gear Removal . . . . . . . . . . . . . . . . . .3.39
Engine Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.44
Engine Cylinder Head Assembly . . . . . . . . . . . . . . . . . .3.28
Engine Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.23
Engine Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.22
Engine Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . . .3.23
Engine Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . .3.18
Engine Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . .3.31
Engine Cylinder Installation . . . . . . . . . . . . . . . . . . . . . .3.45
Engine Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . .3.29
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.19
Engine Exploded Views . . . . . . . 3.2, 3.3, 3.4, 3.5, 3.7, 3.8
Engine Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Engine Flywheel / Stator Installation . . . . . . . . . . . . . . .3.54
Engine Flywheel / Stator Removal . . . . . . . . . . . . . . . . .3.34
Engine Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . .3.35
Engine Gear(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.36
Engine Gears, Installation . . . . . . . . . . . . . . . . . . . . . . . .3.48
Engine Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Engine Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . .3.18
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.23
Engine Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Engine Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Engine Oil Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
Engine Oil Pump Installation . . . . . . . . . . . . . . . . . . . . .3.46
Engine Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . .3.39
Engine Piston Identification . . . . . . . . . . . . . . . . . . . . . .3.14
Engine Piston Installation . . . . . . . . . . . . . . . . . . . . . . . .3.45
Engine Piston Removal, Inspection . . . . . . . . . . . . . . . . 3.30
Engine Piston Ring Installed Gap . . . . . . . . . . . . . . . . . 3.33
Engine Piston to Cylinder Clearance . . . . . . . . . . . . . . . 3.32
Engine Piston to Rod Clearance . . . . . . . . . . . . . . . . . . . 3.32
Engine Pushrod Inspection . . . . . . . . . . . . . . . . . . . . . . . 3.22
Engine Removal / Install Procedure . . . . . . . . . . . . . . . . 3.16
Engine Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . 3.22
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . 3.11
Engine Starter Drive Removal . . . . . . . . . . . . . . . . . . . . 3.33
Engine Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
Engine Stator Gear Cover Seal(s) Installation . . . . . . . . 3.50
Engine Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 4.18
Engine Temperature Sensor Replacement . . . . . . . . . . . 4.18
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . . 4.18
Engine Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
Engine Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Engine Valve Lifter Removal, Inspection . . . . . . . . . . . 3.29
Engine Valve Seal/Spring Service . . . . . . . . . . . . . . . . . 3.23
Engine Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . 3.29
Engine Valve Seat Reconditioning . . . . . . . . . . . . . . . . 3.26
Engine, Accessible Components . . . . . . . . . . . . . . . . . . 3.14
ETC Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
ETC Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Exhaust Breakdown, Sportsman 800 EFI . . . . . . . . . . . 3.59
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Exhaust, 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
Exhaust, Dual 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
F
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.16
Fan Control Circuit Operation / Testing . . . . . . . . . . . 10.16
Fan Motor Current Draw . . . . . . . . . . . . . . . . . . . . . . . 10.17
Final Drive Torque Specifications . . . . . . . . . . . . . . . . . . 7.2
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.34
Flywheel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
Flywheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Foot Well Removal / Installation . . . . . . . . . . . . . . . . . . . 5.5
Frame, Nuts, Bolts Fastener Inspection . . . . . . . . . . . . . 2.30
Front Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.9
Front Cover Removal / Installation . . . . . . . . . . . . . . . . . 5.4
Front Drive Axle Installation . . . . . . . . . . . . . . . . . . . . . . 7.4
Front Drive Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Front Gearcase - Back Lash Pad Adjustment . . . . . . . . 7.18
Front Gearcase Coil Resistance . . . . . . . . . . . . . . .7.14, 7.23
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.12
Front Gearcase, Active Descent Control Exploded View 7.21
Front Gearcase, Diagnoses . . . . . . . . . . . . . . . . . . . . . . . 7.19
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.13
Front Gearcase, Exploded View . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.20
Front Gearcase, Operation . . . . . . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Reassembly . . . . . . . . . . . . . . . . . . . . . 7.29
Front Gearcase, Reassembly / Inspection . . . . . . . . . . . 7.17
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.12
IX.3
IX Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Front Storage Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Front Storage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16, 4.12
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.5
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . . 4.4
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.3
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.2
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . . 4.9
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Fuel System, EFI Circuit Diagrams . . . . . . . . . . . . . . . . 4.21
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
G
Gear / Stator Housing Seal Replacement . . . . . . . . . . . . 3.49
Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.17
Gearcase, ADC Hydraulic Fluid Change . . . . . . . . . . . . 2.14
Gearcase, Front Capacity and Fluid Type . . . . . . . . . . . . 7.2
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
H
Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.16
Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.27
Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.15
High Beam Bulb Replacement . . . . . . . . . . . . . . . . . . . 10.26
High Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.28
Hydraulic Brake System Operation Overview . . . . . . . . . 9.6
I
Ignition Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
Ignition System Troubleshooting . . . . . . . . . . . . . . . . . 10.21
Instrument Cluster (Speedometer) Overview . . . . . . . . . 10.3
Instrument Cluster, Setting New Service Interval . . . . . 10.6
Interlock, Starter, 700/800 EFI . . . . . . . . . . . . . . . . . . . 10.36
Interlock, Starter, 800 X2 EFI . . . . . . . . . . . . . . . . . . . 10.37
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
L
Low Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.29
Low Maintenance Battery Charging . . . . . . . . . . . . . . . 10.50
Low Maintenance Battery Info . . . . . . . . . . . . . . . . . . . 10.50
Lower Headlamp Housing Removal . . . . . . . . . . . . . . 10.29
Lower Headlamp Removal . . . . . . . . . . . . . . . . . . . . . . 10.28
Lubricants/Fluids, Polaris Brand Part Numbers . . . . . . . . 2.9
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
2.10
Lubrication / Grease Points . . . . . . . . . . . . . . . . . . . . . . 2.11
M
Maintenance Chart, Periodic . . . . . . . . . . . . . . . . . . . . . . 2.3
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
Misc. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
Model Number/VIN Identification . . . . . . . . . . . . . . . . . .1.2
O
Oil Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
Oil Pump, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
Passenger Seat, Operation . . . . . . . . . . . . . . . . . . . . . . . .5.29
Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . .3.33
Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . .3.32
Piston to Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . .3.32
Plastic Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
Pre-ride Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drive Clutch Shift Weights . . . . . . . . . . . . . . . . . . .6.9
PVT Drive Clutch Specifications . . . . . . . . . . . . . . . . . . .6.8
PVT Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22, 6.10
PVT Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3
PVT Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . .6.7
PVT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Overheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
PVT Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .6.37
PVT, Button to Tower Clearance . . . . . . . . . . . . . 6.17, 6.30
PVT, Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . .6.13
PVT, Drive Belt Removal/Inspection . . . . . . . . . . . . . . .6.12
PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . 6.15, 6.28
PVT, Drive Clutch Exploded View . . . . . . . . . . . . . . . . . .6.3
PVT, Drive Clutch Reassembly . . . . . . . . . . . . . . 6.20, 6.32
PVT, Drive Clutch Spider Removal . . . . . . . . . . . 6.15, 6.29
PVT, Driven Clutch Bushing Service . . . . . . . . . . . . . . .6.24
PVT, Driven Clutch Disassembly . . . . . . . . . . . . . . . . . .6.22
PVT, Driven Clutch Reassembly . . . . . . . . . . . . . . . . . .6.25
PVT, EBS Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.7
PVT, EBS Drive Clutch Bushing Service . . . . . . . 6.18, 6.31
PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.19,
6.32
PVT, Moveable Sheave Inspection . . . . . . . . . . . . 6.18, 6.31
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
Radiator Screen Removal . . . . . . . . . . . . . . . . . . . . . . . .5.11
Rear Cab Removal / Installation . . . . . . . . . . . . . . . . . . .5.10
Rear Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . .7.41
Rear Gearcase, Disassembly . . . . . . . . . . . . . . . . . . . . . .7.39
Rear Gearcase, Exploded View . . . . . . . . . . . . . . . . . . . .7.43
IX.4
Rear Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . .7.42
Rear Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . .7.39
Rear Master Cylinder, Exploded View . . . . . . . . . . . . . .9.26
Rear Rack Removal / Installation . . . . . . . . . . . . . . . . . . .5.8
Rear Storage Removal / Installation . . . . . . . . . . . . . . . .5.11
Rear Suspension Assembly . . . . . . . . . . . . . . . . . . 5.22, 5.23
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.25
S
See FRONT GEARCASE - CENTRALIZED HILLIARD
(STANDARD on page 7.10. . . . . . . . . . . . . . . . . . . . . . .7.23
Service Intervals, Speedometer . . . . . . . . . . . . . . . . . . . .10.6
Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Special Tool, Cam Gear Installation Kit . . . . . . . . . . . . .3.37
Special Tools, Body & Steering . . . . . . . . . . . . . . . . . . . .5.2
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Special Tools, Speed Sensor . . . . . . . . . . . . . . . . . . . . .10.34
Specific Gravity Test, Conventional Battery . . . . . . . .10.48
Specification, Balance Shaft Gear Bolt Torque . . . . . . .3.48
Specification, Brake Disc Service Limit . . . . . . . . . . . . .9.25
Specification, Brake Disc Thickness . . . . . . . . . . . . . . . .9.25
Specification, Brake Pad Thickness . . . . . . . . . . . . . . . .9.19
Specification, Cam Lobe Height . . . . . . . . . . . . . . . . . . .3.42
Specification, Cam Thrust Plate Fastener Torque . . . . . .3.46
Specification, Camshaft Gear Bolt Torque . . . . . . . . . . .3.49
Specification, Coolant Sensor Resistance . . . . . . . . . . .10.16
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.23
Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . .3.31
Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . .3.31
Specification, Differential Solenoid Resistance 10.33, 10.34
Specification, Differential Solenoid Torque . . . 10.33, 10.34
Specification, Drill and Tap Sizes . . . . . . . . . . . . . . . . . .1.13
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.47
Specification, Oil Pump Rotor Clearance . . . . . . . . . . . .3.40
Specification, PVT Center-to-Center Distance . . . . . . . .6.13
Specification, PVT Component Torque Table . . . . . . . . .6.2
Specification, PVT Drive Belt Width . . . . . . . . . . . . . . .6.13
Specification, Speed Sensor Bolt Torque . . . . . . . . . . .10.34
Specification, Standard Fastener Torques . . . . . . . . . . . .1.12
Specification, Timing Gear Alignment . . . . . . . . . . . . . .3.36
Specification, Transmission Silent Chain Length . . . . . .8.35
Specification, Valve Seat Contact Width . . . . . . . . . . . .3.27
Specification, Valve Spring Free Length . . . . . . . . . . . .3.24
Specification, Valve Stem Diameter . . . . . . . . . . . . . . . .3.25
Specification, Valve Stem Guide I.D. . . . . . . . . . . . . . . .3.25
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . . . .2.25
Specifications, Body and Steering Torque Values . . . . . .5.2
Specifications, Brake Component Service Limits . . . . . . .9.2
Specifications, Brake Component Torque Values . . . . . .9.2
Specifications, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . .3.43
Specifications, Cooling System . . . . . . . . . . . . . . . . . . . .3.14
Specifications, Crankcase Fastener Torque . . . . . . . . . . .3.44
Specifications, Engine Lubrication . . . . . . . . . . . . . . . . 3.20
Specifications, Engine Oil Pressure . . . . . . . . . . . . . . . . 3.20
Specifications, Final Drive Torque Values . . . . . . . . . . . 7.2
Specifications, Front Gearcase Lubrication Type/Capacity 7.2
Specifications, Oil Baffle Bolt Torque . . . . . . . . . . . . . 3.43
Specifications, Oil Pick-up Bolt Torque . . . . . . . . . . . . 3.43
Specifications, Sportsman 700 EFI . . . . . . . . . . . . . . . . . 1.6
Specifications, Sportsman 800 EFI . . . . . . . . . . . . . . . . . 1.8
Specifications, Sportsman 800 X2 EFI . . . . . . . . . . . . . 1.10
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Speedometer Sensor, Replacement . . . . . . . . . . . . . . . 10.34
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . 10.10
Speedometer, Funtions Overview . . . . . . . . . . . . . . . . . 10.3
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . 10.40
Starter Assembly Exploded View . . . . . . . . . . . . . . . . 10.43
Starter Brush Inspection / Replacement . . . . . . . . . . . . 10.39
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Starter Interlock . . . . . . . . . . . . . . . . . . . . . . . . .10.36, 10.37
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . 10.38
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . 10.41
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . . 10.44
Starter System, Troubleshooting . . . . . . . . . . . . . . . . . 10.38
Stator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Steering A-Arm Exploded View . . . . . . . . . . . . . . . . . . 5.17
Steering Lock, Exploded View . . . . . . . . . . . . . . . . . . . 11.4
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Steering Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
pecno1 Storage Compartments, Front & Rear . . . . . . . . . . . . . . 2.30
Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Strut Cartridge Replacement, Front . . . . . . . . . . . . . . . . 5.20
Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Suspension, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Suspension, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
T
Temperature / Barometric Air Pressure Sensor (T-Bap) 4.15
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Throttle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.16
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.15
Tie Rod / Steering Inspection . . . . . . . . . . . . . . . . . . . . . 2.24
Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . 3.36
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Torque Specs - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 8.7
Transmission Exploded View . . . . . . . . . . . . . . . . . . . . . 8.4
Transmission Gear Selector Removal . . . . . . . . . . . . . . . 8.6
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . 8.17
IX.5
IX Transmission Mounts, Exploded View . . . . . . . . . . . . . 8.22
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . 8.18
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . 8.27
Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . 8.20
Transmission, Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Transmission, Output Shaft Backlash Procedure . . . . . . 8.33
Transmission, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8.32
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
Transmission, Special Tools . . . . . . . . . . . . . . . . . . . . . . 8.23
Troubleshooting, EFI Circuit Diagrams . . . . . . . . . . . . . 4.21
U
U-joint, Disassembly and Assembly . . . . . . . . . . . . . . . . 7.7
V
Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.23
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.26
Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
W
Warn Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Winch, Basic Wiring Diagram . . . . . . . . . . . . . . . . . . . 10.45
Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
X
X2, Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30

----------------------------------------------------------------------------------------------

DESCRIPTION:
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2007 POLARIS SPORTSMAN 800 X2 EFI,
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