2007 POLARIS SPORTSMAN 700 800 800 X2 EFI ( 700 & 800 TWIN MODELS ) SERVICE | REPAIR | SHOP MANUAL – DOWNLOAD – 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 !! )

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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

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

——–

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