2008 Polaris Sportsman X2 700 / 800 EFI / 800 Touring Factory Service / Repair / Maintenance Manual 08 – DOWNLOAD (55 MB) – 89698863

2008 Polaris Sportsman X2 700 / 800 EFI / 800 Touring Factory Service / Repair / Maintenance Manual – DOWNLOAD (55 MB) !

( VERY HIGH QUALITY FACTORY SERVICE MANUAL – 55+ MB !! )

File Format: PDF

Compatible: All Versions of Windows & Mac

Downloadable: YES

Language: English

Requirements: Adobe PDF Reader.

Pages: 388 +

SERVICE MANUAL COVERS:

GENERAL 1

MAINTENANCE 2

ENGINE 3

FUEL SYSTEM 4

BODY / SUSPENSION 5

CLUTCH 6

TRANSMISSION 7

FINAL DRIVE 8

BRAKES 9

ELECTRICAL 10

INTERNATIONAL 11

INDEPTH CONTENTS WITH ACTUAL PAGE / SUBSECTION NUMBERS:

A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

Accessory Power Wiring . . . . . . . . . . . . . . . . . . . . . . . 10.35

Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.15

Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.13

ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.21

ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.17

ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.18

Air Box Sediment Tube . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.15

Alternator / Ignition Components . . . . . . . . . . . . . . . . . 10.20

Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

Auxiliary (Rear) Brake Test . . . . . . . . . . . . . . . . . . . . . . 2.28

Auxiliary Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . 2.29

Axle, Front Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

B

Balance Shaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . 3.38

Ball Joint Replacement, Front . . . . . . . . . . . . . . . . . . . . 5.21

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

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, 5.14, 5.16

Body Rack Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.15

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 . . . . . . . . . . . . . . . . . . . . 2.28

Brake Light / Work Light Switch Replacement 10.30, 10.31

Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32

Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.7

Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

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 . . . . . . . . . . . . . . . . . . . . . . . . .2.27

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

Cargo Box, Removal and Installation . . . . . . . . . . . . . . .5.28

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 . . . . . . . . . . . . . . . . . . . . .2.34

Clock, Setting Time of Day . . . . . . . . . . . . . . . . . . . . . . .10.4

Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14

Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14

Clutch, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6.29

Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

Component Locations, Sportsman . . . . . . . . . . . . . . . . . .2.7

Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

Cooling System – Coolant Level . . . . . . . . . . . . . . . . . . .2.20

Cooling System – Pressure Test . . . . . . . . . . . . . . . . . . .2.20

Cooling System – Radiator Level . . . . . . . . . . . . . . . . . .2.21

Cooling System Bleeding Procedure . . . . . . . . . . . . . . . .3.15

Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

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 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5

CV Boot, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5

CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.29

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

IX.2

Drive Belt, Removal/Inspection . . . . . . . . . . . . . . . . . . .6.12

Drive Clutch Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8

Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9

Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.6

Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.6

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 . . . . . . . . . . . . . . . . . . . . . . . . . .4.8

EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . . .4.8

EFI Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20

Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . .4.9

Elelctrical, Troubleshooting Diagrams . . . . . . . . . . . . .10.54

Engine Balance Shaft Removal . . . . . . . . . . . . . . . . . . . .3.42

Engine Breather Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

Engine Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.55

Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . .3.18

Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.24

Engine Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

Exhaust, 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

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 . . . . . . . . . . . . . 2.31

Front Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.9

Front Cover Removal / Installation . . . . . . . . . . . . . . . . . 5.4

Front CV Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . 7.4

Front CV Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Front Gearcase Coil Resistance . . . . . . . . . . . . . . . . . . . 7.17

Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.12

Front Gearcase, Active Descent Control Exploded View 7.12

Front Gearcase, Diagnoses . . . . . . . . . . . . . . . . . . . . . . . 7.14

Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.16

Front Gearcase, Reassembly . . . . . . . . . . . . . . . . . . . . . 7.23

Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

Front Storage Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

Front Storage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17, 4.12

Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.6

Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . . 4.5

Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.4

Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.2

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.10

Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33

Fuel System, EFI Circuit Diagrams . . . . . . . . . . . . . . . . 4.21

Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

G

Gear / Stator Housing Seal Replacement . . . . . . . . . . . . 3.49

Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.17

Gearcase, ADC Hydraulic Fluid Change . . . . . . . . . . . . 2.15

Gearcase, Front Capacity and Fluid Type . . . . . . . . . . . . 7.2

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

H

Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.18

Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.27

Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.17

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 . . . . . . . . . . . . . . . . . . . . . 2.37, 2.38

Misc. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

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 . . . . . . . . . . . . . . . . . . . . . . . .5.31

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23, 6.10

PVT Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3

PVT Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . .6.7

PVT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6

PVT Overheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . .6.29

PVT Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2

PVT Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2

PVT Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .6.30

PVT, Button to Tower Clearance . . . . . . . . . . . . . . . . . .6.17

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

PVT, Drive Clutch Exploded View . . . . . . . . . . . . . . . . . .6.3

PVT, Drive Clutch Reassembly . . . . . . . . . . . . . . . . . . .6.20

PVT, Drive Clutch Spider Removal . . . . . . . . . . . . . . . .6.15

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

PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.19

PVT, Moveable Sheave Inspection . . . . . . . . . . . . . . . . .6.18

R

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

Radiator Screen Removal . . . . . . . . . . . . . . . . . . . . . . . .5.11

Rear Cab Removal / Installation . . . . . . . . . . . . . . . . . . .5.10

Rear Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . .2.13

Rear Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . .7.35

Rear Gearcase, Disassembly . . . . . . . . . . . . . . . . . . . . . .7.34

Rear Gearcase, Exploded View . . . . . . . . . . . . . . . . . . . .7.38

Rear Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . .7.36

Rear Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . .7.34

Rear Master Cylinder, Exploded View . . . . . . . . . . . . . .9.26

Rear Rack Removal / Installation . . . . . . . . . . . . . . . . . . .5.8

Rear Storage Removal / Installation . . . . . . . . . . . . . . . .5.11

IX.4

Rear Suspension Assembly . . . . . . . . . . . . . . . . . . 5.24, 5.25

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.25

S

See FRONT GEARCASE – CENTRALIZED HILLIARD

(STANDARD on page 7.10. . . . . . . . . . . . . . . . . . . . . . .7.17

Service Intervals, Speedometer . . . . . . . . . . . . . . . . . . . .10.6

Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.15

Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4

Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . .10.33

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

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 . . . . . . . . . . . . . . . . . .1.11

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 . . . . . . . . . . . .1.10

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 . . . . . . . . . . . . . . . . . . . . .2.26

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 800 EFI . . . . . . . . . . . . . . . . . 1.4

Specifications, Sportsman Touring . . . . . . . . . . . . . . . . . 1.8

Specifications, Sportsman X2 . . . . . . . . . . . . . . . . . . . . . 1.6

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

Steering A-Arm Exploded View . . . . . . . . . . . . . . . . . . 5.19

Steering Lock, Exploded View . . . . . . . . . . . . . . . . . . . 11.4

Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.22

Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22

Steering Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

Storage Compartments, Front & Rear . . . . . . . . . . . . . . 2.31

Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23

Strut Cartridge Replacement, Front . . . . . . . . . . . . . . . . 5.22

Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

Suspension, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

Suspension, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

T

Temperature / Barometric Air Pressure Sensor (T-Bap) 4.15

Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Throttle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.16

Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.15

Tie Rod / Steering Inspection . . . . . . . . . . . . . . . . . . . . . 2.25

Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . 3.36

Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

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

Transmission Mounts, Exploded View . . . . . . . . . . . . . 8.22

Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . 8.18

Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . 8.27

Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . 8.20

IX.5

IX 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 Diagrams, Elelctrical . . . . . . . . . . . . . 10.54

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38

W

Warn Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

Winch, Basic Wiring Diagram . . . . . . . . . . . . . . . . . . . 10.45

Wire Diagrams, Electrical . . . . . . . . . . . . . . . . . . . . . . 10.54

Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30

X

X2, Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

ALL INFORMATION ARE FULLY SEARCHABLE AND COMPLETELY INDEXED FOR EASY NAVIGATION AND USE… 🙂

WARNING:

DO NOT BUY ANY OTHER INFERIOR QUALITY MANUAL SOLD AS FACTORY SERVICE MANUAL ELSEWHERE!! YOU WOULD NOT ONLY LOOSE YOUR MONEY BUT ALSO YOUR VALUABLE TIME SEARCHING FOR INFORMATION IN IT…

Description:

COVERS ALL MODELS & ALL REPAIRS A-Z

THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.

COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!

YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE CD-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.

ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES!

FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.

ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!

INFORMATION YOU CAN COUNT ON !!

Related Customer Searches:

2008 Polaris Sportsman X2 700 / 800 EFI / 800 Touring Factory Service Repair Maintenance Manual 08, polaris, service, repair, 2008 POLARIS SPORTSMAN X2 700 800 SERVICE MANUAL, Polaris Repair Manual, Sportsman Touring 800 EFI International Service Manual, 2008 Polaris Sportsman X2 700 EFI Specifications, Sportsman 800 EFI Specs, Polaris 2008 Polaris Sportsman 800, 2008 Polaris Sportsman 700 X2 , 800 Touring, 2008 Polaris Sportsman 800 Touring, 2008 Polaris Sportsman 800 Sportsman 700 Touring 800 Service Repair Manual

—-

GET THIS MANUAL NOW! & COMPLETE YOUR REPAIRS BY TODAY! FULL VALUE FOR MONEY!!

!!

Tags: 2008 polaris sportsman x2 700 800 efi 800 touring factory service repair maintenance manual 08, 2008 polaris sportsman x2 700 800 service manual, polaris repair manual, sportsman touring 800 efi international service manual, 2008 polaris sportsman x2 700 efi specifications, sportsman 800 efi specs, polaris 2008 polaris sportsman 800, 2008 polaris sportsman 700 x2, 800 touring, 2008 polaris sportsman 800 touring, sportsman, 2008, x2, 700, efi, 800, touring, factory, maintenance, manual, 08, download,

User tags:
2008 polaris sportsman x2 700 800 efipolarisrepairservice

• Latest Products

  • 2009 ARCTIC CAT SERVICE / REPAIR / SHOP MANUAL – COVERS: 400 TRV, 500 AUTOMATIC, 500 MANUAL, 550 H1, 550 H1 TRV, 700H1, 700 H1 – 93894399
  • 2004 Suzuki Gsxr750 Service Manual Gsx-r750 Gsxr 750 DIY Repair Workshop Manual 40 MB DOWNLOAD – 87838454
  • 2004 NISSAN FRONTIER DIY SERVICE / REPAIR / WORKSHOP MANUAL – INSTANT DOWNLOAD 2000+ Pages PDF MANUAL – 117009770
  • Suzuki Burgman AN650 650 Service Manual / DIY Workshop / Repair Manual (28 MB) – DOWNLOAD NOW ! 2003 2004 2005 2006 – 87838174
  • New Copywriting Secrets From The Master AudioBook MP3 200MB 100Mins EBook with Private Label Rights – 9133443
  • SUZUKI GN400 MOTORCYCLE FACTORY SERVICE / REPAIR MANUAL SUPPLEMENT – GN 400 – PDF – INSTANT DOWNLOAD – 97159274
  • Suzuki RF600 RF 600 Repair Manual Service Maintenance Manual – 17 MB Download 1993 1994 1995 1996 1997 1998 1999 – 87837874
  • ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE ENGINE )- ISUZU TRUCK FORWARD TILTMASTER – SERVICE / REPAIR / WORKSHOP MANUAL – 140069122
  • NEW PDF DOMINATION(160MB) Video Course 12 Videos with Master Resale Rights MRR – 9202827
  • 1999 2000 2001 ISUZU CHEVY GMC NPR NPR HD NQR W500 W4500 W5500 4HE1-TC 4HE1 TC 4HE1TC DIESEL ENGINE SERVICE / REPAIR / WORKSHOP – 140068494

• By Category

  • Arctic Cat
  • BMW
  • Bombardier
  • Chevrolet
  • Cub Cadet
  • Cummins
  • Daewoo
  • Daihatsu
  • Digital Files
  • Dodge
  • Fiat
  • GMC
  • Honda
  • Husqvarna
  • Infiniti
  • Isuzu
  • Jeep
  • Johnson Evinrude
  • Kia
  • Kubota
  • Kymco
  • Lamborgini
  • Linhai
  • Mercedes
  • Mitsubishi
  • Nissan
  • Polaris
  • Porsche
  • Sportsman
  • Subaru
  • Suzuki
  • Volkswagen
  • Yamaha