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2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL – PDF DOWNLOAD
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Description
2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:393
DOWNLOADABLE:YES
FILE TYPE:PDF
TABLE OF CONTENTS:
2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL
FOREWORD........................................................................................................................................................................................................ 1 understanding manual safety labels and directions........................................................................................................................................................... 2 TRADEMARKS.................................................................................................................................................................................................. 2 CHAPTER INDEX................................................................................................................................................................................................... 3 CH 1 - GENERAL INFORMATION...................................................................................................................................................................................... 5 MODEL INFORMATION........................................................................................................................................................................................... 6 Model Number/VIN Identification............................................................................................................................................................................. 6 Model Number............................................................................................................................................................................................ 6 Engine Designation Numbers.............................................................................................................................................................................. 6 VIN Identification...................................................................................................................................................................................... 6 TRANSMISSION I.D. LOCATION.............................................................................................................................................................................. 6 Engine and Machine Serial Numbers....................................................................................................................................................................... 6 PUBLICATIONS............................................................................................................................................................................................ 7 Publication Numbers..................................................................................................................................................................................... 7 PAINT CODES............................................................................................................................................................................................. 7 Paint Codes............................................................................................................................................................................................. 7 REPLACEMENT KEYS........................................................................................................................................................................................ 7 Keys, Replacement....................................................................................................................................................................................... 7 Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison............................................................................................................................................ 8 Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison......................................................................................................................................... 9 2007 SPORTSMAN 700 EFI...................................................................................................................................................................................... 10 Specifications, Sportsman 700 EFI........................................................................................................................................................................... 10 MODEL NUMBER: A07MH68AX, AY, AZ ........................................................................................................................................................................ 10 2007 SPORTSMAN 800 EFI...................................................................................................................................................................................... 12 Specifications, Sportsman 800 EFI........................................................................................................................................................................... 12 MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA............................................................................................................................................. 12 2007 SPORTSMAN X2 800 EFI................................................................................................................................................................................... 14 Specifications, Sportsman 800 X2 EFI........................................................................................................................................................................ 14 MODEL NUMBER: A07TH76AU, A07TN76AF...................................................................................................................................................................... 14 Misc. Tables................................................................................................................................................................................................ 16 MISC. NUMBERS/CHARTS........................................................................................................................................................................................ 16 Standard Torque Specifications.......................................................................................................................................................................... 16 Specification, Standard Fastener Torques................................................................................................................................................................ 16 SPECIAL TOOLS........................................................................................................................................................................................... 16 SAE Tap Drill Sizes..................................................................................................................................................................................... 17 Specification, Drill and Tap Sizes...................................................................................................................................................................... 17 Metric Tap Drill Sizes.................................................................................................................................................................................. 17 Decimal Equivalents..................................................................................................................................................................................... 17 Conversion Table........................................................................................................................................................................................ 18 Conversion Table........................................................................................................................................................................................ 18 Glossary Of Terms....................................................................................................................................................................................... 19 Glossary of Terms....................................................................................................................................................................................... 19 CH 2 - MAINTENANCE ............................................................................................................................................................................................. 21 MAINTENANCE................................................................................................................................................................................................. 23 Maintenance Chart, Periodic................................................................................................................................................................................. 23 Overview................................................................................................................................................................................................ 23 Periodic Maintenance Chart.............................................................................................................................................................................. 24 LUBRICATION / FLUIDS........................................................................................................................................................................................ 27 SPORTSMAN Component Locations........................................................................................................................................................................... 27 Component Locations, Sportsman.......................................................................................................................................................................... 0 SPORTSMAN X2 Component Locations........................................................................................................................................................................ 28 Component Locations..................................................................................................................................................................................... 0 Polaris Lubricants, Maintenance and Service Products.................................................................................................................................................... 29 Lubricants/Fluids, Polaris Brand Part Numbers........................................................................................................................................................... 29 Polaris Lubricant Symbol Identification................................................................................................................................................................. 30 Lubricants/Fluids, Polaris Brand Symbol Identification Chart............................................................................................................................................ 30 Pre-Ride / Daily Inspection............................................................................................................................................................................. 30 Pre-ride Checklist...................................................................................................................................................................................... 30 Lubrication / Grease Points............................................................................................................................................................................. 31 Lubrication / Grease Points............................................................................................................................................................................. 31 Front Gearcase Lubrication.............................................................................................................................................................................. 32 Front Gearcase Lubrication.............................................................................................................................................................................. 32 Transmission Lubrication ............................................................................................................................................................................... 33 ADC Differential Hydraulic Circuit Fluid Change......................................................................................................................................................... 34 Gearcase, ADC Hydraulic Fluid Change.................................................................................................................................................................... 34 VEHICLE INSPECTION.......................................................................................................................................................................................... 34 Shift Link Rod Inspection............................................................................................................................................................................... 34 Shift Linkage Inspection................................................................................................................................................................................ 34 Throttle Inspection..................................................................................................................................................................................... 35 Throttle Inspection..................................................................................................................................................................................... 35 Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment.................................................................................................................................... 35 Throttle Cable.......................................................................................................................................................................................... 35 Fuel System............................................................................................................................................................................................. 36 Fuel Filter............................................................................................................................................................................................. 36 Vent Lines.............................................................................................................................................................................................. 36 Vent Lines.............................................................................................................................................................................................. 36 Compression Test........................................................................................................................................................................................ 36 Compression Test........................................................................................................................................................................................ 36 Engine Mounts........................................................................................................................................................................................... 37 Engine Mount............................................................................................................................................................................................ 37 Spark Plug ............................................................................................................................................................................................. 37 Spark Plug.............................................................................................................................................................................................. 37 Active Descent Control (ADC) Reservoir Level............................................................................................................................................................ 37 ADC reservoir level inspection.......................................................................................................................................................................... 37 Battery Maintenance..................................................................................................................................................................................... 38 Battery Maintenance..................................................................................................................................................................................... 38 Cooling System.......................................................................................................................................................................................... 38 Cooling System.......................................................................................................................................................................................... 38 Coolant Strength / Type................................................................................................................................................................................. 39 Cooling Hoses........................................................................................................................................................................................... 39 Cooling System Hoses.................................................................................................................................................................................... 39 Radiator................................................................................................................................................................................................ 39 Radiator................................................................................................................................................................................................ 39 Cooling System Pressure Test............................................................................................................................................................................ 39 Cooling System - Pressure Test.......................................................................................................................................................................... 39 Reservoir Level Inspection.............................................................................................................................................................................. 39 Cooling System - Coolant Level.......................................................................................................................................................................... 39 Radiator Coolant Level.................................................................................................................................................................................. 40 Cooling System - Radiator Level......................................................................................................................................................................... 40 Air Filter Service...................................................................................................................................................................................... 40 Air Filter Service...................................................................................................................................................................................... 40 Air Box Sediment Tube................................................................................................................................................................................... 41 Air Box Sediment Tube................................................................................................................................................................................... 41 Engine Breather......................................................................................................................................................................................... 41 Engine Breather Hoses................................................................................................................................................................................... 41 PVT Inspection / Drying Procedure....................................................................................................................................................................... 42 PVT Drying.............................................................................................................................................................................................. 42 Engine Ground........................................................................................................................................................................................... 42 Engine Ground........................................................................................................................................................................................... 42 Engine Oil Level........................................................................................................................................................................................ 42 Engine Oil Level........................................................................................................................................................................................ 42 Oil/filter Change....................................................................................................................................................................................... 43 Engine Oil and Filter Change............................................................................................................................................................................ 43 Steering Inspection..................................................................................................................................................................................... 44 Steering................................................................................................................................................................................................ 44 Tie Rod / Steering...................................................................................................................................................................................... 44 Tie Rod / Steering Inspection........................................................................................................................................................................... 44 Camber/Caster........................................................................................................................................................................................... 44 Camber / Caster......................................................................................................................................................................................... 44 Wheel Alignment......................................................................................................................................................................................... 45 Wheel Alignment......................................................................................................................................................................................... 45 Specification, Wheel Toe-Out........................................................................................................................................................................ 0 Toe Alignment........................................................................................................................................................................................... 45 Exhaust Pipe............................................................................................................................................................................................ 46 Exhaust Pipe............................................................................................................................................................................................ 46 Brake System Inspection................................................................................................................................................................................. 46 Brake System Inspection................................................................................................................................................................................. 46 Brake Pads.............................................................................................................................................................................................. 47 Brake Pad Inspection.................................................................................................................................................................................... 47 Brake Hose Inspection................................................................................................................................................................................... 47 Brake Hose Fitting Inspection........................................................................................................................................................................... 47 Auxiliary (Rear) Brake Test............................................................................................................................................................................. 47 Auxiliary (Rear) Brake Test............................................................................................................................................................................. 47 Auxiliary Brake Adjustment.............................................................................................................................................................................. 48 Auxiliary Brake Adjustment.............................................................................................................................................................................. 48 Suspension: Spring Preload Adjustment................................................................................................................................................................... 48 Suspension Adjustment.................................................................................................................................................................................. 48 Front Suspension........................................................................................................................................................................................ 48 Suspension, Front....................................................................................................................................................................................... 48 Rear Suspension......................................................................................................................................................................................... 48 Suspension, Rear........................................................................................................................................................................................ 48 CV Shaft Boot Inspection................................................................................................................................................................................ 48 CV Shaft Boot Inspection................................................................................................................................................................................ 48 ATV Controls............................................................................................................................................................................................ 49 Wheel Inspection........................................................................................................................................................................................ 49 Wheel Removal: Front Or Rear............................................................................................................................................................................ 49 Wheel Removal........................................................................................................................................................................................... 49 Wheel Installation...................................................................................................................................................................................... 49 Wheel Installation...................................................................................................................................................................................... 49 Tire Pressure........................................................................................................................................................................................... 50 Tire Inspection......................................................................................................................................................................................... 50 Tire Inspection......................................................................................................................................................................................... 50 Frame, Nuts, Bolts, Fasteners........................................................................................................................................................................... 50 Frame, Nuts, Bolts Fastener Inspection.................................................................................................................................................................. 50 Front / Rear Storage Compartments....................................................................................................................................................................... 50 Storage Compartments, Front & Rear...................................................................................................................................................................... 50 Winch Operation (If Equipped)........................................................................................................................................................................... 51 Warn Winch Operation.................................................................................................................................................................................... 51 Cleaning And Storage Of ATV............................................................................................................................................................................. 53 Cleaning and Storage of ATV............................................................................................................................................................................. 53 Exhaust, 800 EFI........................................................................................................................................................................................ 55 Maintenance Schedule.................................................................................................................................................................................... 56 Maintenance Schedule.................................................................................................................................................................................... 56 CH 3 - ENGINE................................................................................................................................................................................................... 57 SPECIFICATIONS.............................................................................................................................................................................................. 58 Crankcase Exploded Views................................................................................................................................................................................ 58 Engine Exploded Views................................................................................................................................................................................... 59 Engine Exploded Views................................................................................................................................................................................... 59 Engine Exploded Views................................................................................................................................................................................... 60 Engine Exploded Views................................................................................................................................................................................... 61 Engine Exploded Views................................................................................................................................................................................... 62 Engine Exploded Views................................................................................................................................................................................... 64 Engine Exploded Views................................................................................................................................................................................... 64 Engine Fastener Torque Patterns......................................................................................................................................................................... 65 Engine Fastener Torques................................................................................................................................................................................. 0 Torque Specifications................................................................................................................................................................................... 66 Engine Torque Table..................................................................................................................................................................................... 66 Torque Specs - Engine................................................................................................................................................................................... 66 700/800 EFI Engine Service Specifications............................................................................................................................................................... 67 Engine Service Specifications........................................................................................................................................................................... 67 Special Tools........................................................................................................................................................................................... 69 Special Tools, Engine................................................................................................................................................................................... 69 GENERAL ENGINE SERVICE...................................................................................................................................................................................... 70 Accessible Components................................................................................................................................................................................... 70 Engine, Accessible Components........................................................................................................................................................................... 70 Piston Identification................................................................................................................................................................................... 70 Engine Piston Identification............................................................................................................................................................................ 70 Cooling System Specifications........................................................................................................................................................................... 70 Cooling System Specifications........................................................................................................................................................................... 70 Specifications, Cooling System.......................................................................................................................................................................... 70 Engine Cooling System................................................................................................................................................................................... 70 Cooling System Pressure Test............................................................................................................................................................................ 71 Cooling System, Pressure Test........................................................................................................................................................................... 71 Engine Cooling System................................................................................................................................................................................... 71 Four Stroke - Coolant Air Bleeding Procedure............................................................................................................................................................ 71 Cooling System Bleeding Procedure....................................................................................................................................................................... 71 Engine Removal (Typical)................................................................................................................................................................................ 72 Engine Removal / Install Procedure...................................................................................................................................................................... 72 Engine Installation Notes............................................................................................................................................................................... 74 Engine Installation Notes............................................................................................................................................................................... 74 Cylinder Hone Selection And Honing Procedure............................................................................................................................................................ 74 Engine Cylinder Honing.................................................................................................................................................................................. 74 Honing To Deglaze....................................................................................................................................................................................... 75 Cylinder Honing To De-glaze............................................................................................................................................................................. 75 Cleaning the Cylinder After Honing...................................................................................................................................................................... 75 Oil Flow Chart.......................................................................................................................................................................................... 76 Engine Oil Flow Chart................................................................................................................................................................................... 76 Engine Lubrication Specifications....................................................................................................................................................................... 76 Specifications, Engine Lubrication...................................................................................................................................................................... 76 Engine Lubrication...................................................................................................................................................................................... 76 OIL PRESSURE TEST....................................................................................................................................................................................... 76 Engine Oil Pressure Test................................................................................................................................................................................ 76 Specifications, Engine Oil Pressure................................................................................................................................................................. 76 ENGINE DISASSEMBLY AND INSPECTION........................................................................................................................................................................... 77 Cylinder Head Assembly Exploded View.................................................................................................................................................................... 77 Cylinder Head Assembly Exploded View.................................................................................................................................................................... 0 Rocker Arms............................................................................................................................................................................................. 78 Engine Rocker Arm Inspection............................................................................................................................................................................ 78 Push Rods............................................................................................................................................................................................... 78 Engine Pushrod Inspection.............................................................................................................................................................................. 78 Cylinder Head Removal .................................................................................................................................................................................. 78 Engine Cylinder Head Removal........................................................................................................................................................................... 78 Cylinder Head Inspection................................................................................................................................................................................ 79 Engine Cylinder Head Inspection......................................................................................................................................................................... 79 Cylinder Head Warp...................................................................................................................................................................................... 79 Engine Cylinder Head Warp............................................................................................................................................................................... 79 Specification, Cylinder Head Warp................................................................................................................................................................... 79 Valve Seal/Spring Service (On Engine)................................................................................................................................................................... 79 Valve Seal/Spring Service............................................................................................................................................................................... 79 Engine Valve Seal/Spring Service........................................................................................................................................................................ 79 Cylinder Head Disassembly............................................................................................................................................................................... 80 Cylinder Head Disassembly............................................................................................................................................................................... 80 Specification, Valve Spring Free Length............................................................................................................................................................. 80 Valve Inspection........................................................................................................................................................................................ 81 Engine Valve Inspection................................................................................................................................................................................ 81 Specification, Valve Stem Diameter.................................................................................................................................................................. 81 Specification, Valve Stem Guide I.D................................................................................................................................................................. 81 Combustion Chamber...................................................................................................................................................................................... 82 Combustion Chamber...................................................................................................................................................................................... 82 Valve Seat Reconditioning............................................................................................................................................................................... 82 Valve Seat Reconditioning............................................................................................................................................................................... 82 Engine Valve Seat Reconditioning....................................................................................................................................................................... 82 Specification, Valve Seat Contact Width............................................................................................................................................................. 83 Cylinder Head Reassembly................................................................................................................................................................................ 84 Engine Cylinder Head Assembly.......................................................................................................................................................................... 84 Cylinder Head Assembly.................................................................................................................................................................................. 84 Valve Sealing Test...................................................................................................................................................................................... 85 Engine Valve Sealing Test............................................................................................................................................................................... 85 Valve Sealing Test...................................................................................................................................................................................... 85 Cylinder Removal........................................................................................................................................................................................ 85 Engine Cylinder Removal................................................................................................................................................................................. 85 Valve Lifter Removal/Inspection......................................................................................................................................................................... 85 Engine Valve Lifter Removal, Inspection................................................................................................................................................................. 85 Piston Removal.......................................................................................................................................................................................... 86 Engine Piston Removal, Inspection....................................................................................................................................................................... 86 Cylinder Inspection..................................................................................................................................................................................... 87 Engine Cylinder Inspection.............................................................................................................................................................................. 87 Cylinder Inspection..................................................................................................................................................................................... 87 Specification, Cylinder Warp Limit.................................................................................................................................................................. 87 Specification, Cylinder Taper Limit................................................................................................................................................................. 87 Piston-To-Cylinder Clearance............................................................................................................................................................................ 88 Piston to Cylinder Clearance............................................................................................................................................................................ 88 Engine Piston to Cylinder Clearance..................................................................................................................................................................... 88 Piston/rod Inspection................................................................................................................................................................................... 88 Engine Piston to Rod Clearance.......................................................................................................................................................................... 88 Piston to Rod Inspection................................................................................................................................................................................ 88 Piston Ring Installed Gap............................................................................................................................................................................... 89 Piston Ring Installed Gap............................................................................................................................................................................... 89 Engine Piston Ring Installed Gap........................................................................................................................................................................ 89 Starter Drive/Bendix Removal Inspection ................................................................................................................................................................ 89 Starter Drive Removal................................................................................................................................................................................... 89 Engine Starter Drive Removal............................................................................................................................................................................ 89 Flywheel / Stator Removal / Inspection.................................................................................................................................................................. 90 Stator, Removal......................................................................................................................................................................................... 90 Flywheel, Removal....................................................................................................................................................................................... 90 Flywheel / Stator Removal............................................................................................................................................................................... 90 Engine Flywheel / Stator Removal....................................................................................................................................................................... 90 Engine Crankcase Disassembly / Inspection............................................................................................................................................................... 91 Engine Flywheel Removal............................................................................................................................................................................. 91 Engine Starter Removal.............................................................................................................................................................................. 91 Engine Gear(s) Removal.............................................................................................................................................................................. 92 Specification, Timing Gear Alignment................................................................................................................................................................ 92 Timing Gear Mark Alignment.......................................................................................................................................................................... 92 Cam Gear, Removal................................................................................................................................................................................... 92 Cam Gear, Reassembly................................................................................................................................................................................ 93 Special Tool, Cam Gear Installation Kit............................................................................................................................................................. 93 Balance Shaft Gear, Removal......................................................................................................................................................................... 94 Crankshaft Gear, Removal............................................................................................................................................................................ 95 Engine Crankshaft Gear Removal...................................................................................................................................................................... 95 Oil Pump, Removal................................................................................................................................................................................... 95 Engine Oil Pump Removal............................................................................................................................................................................. 95 Oil Pump, Disassembly............................................................................................................................................................................... 95 Specification, Oil Pump Rotor Clearance............................................................................................................................................................. 96 Oil Pump, Reassembly................................................................................................................................................................................ 96 Engine Balance Shaft Removal........................................................................................................................................................................ 98 Camshaft Inspection..................................................................................................................................................................................... 98 Engine Camshaft Inspection.............................................................................................................................................................................. 98 Specification, Cam Lobe Height...................................................................................................................................................................... 98 Specifications, Cam Shaft........................................................................................................................................................................... 99 ENGINE REASSEMBLY........................................................................................................................................................................................... 99 CRANKCASE REASSEMBLY.................................................................................................................................................................................... 99 Engine Crankcase Assembly............................................................................................................................................................................... 99 Specifications, Oil Baffle Bolt Torque.............................................................................................................................................................. 99 Specifications, Oil Pick-up Bolt Torque............................................................................................................................................................. 99 Engine Camshaft Installation........................................................................................................................................................................100 Engine Crankshaft Installation......................................................................................................................................................................100 Specifications, Crankcase Fastener Torque...........................................................................................................................................................100 Engine Cylinder Installation........................................................................................................................................................................101 Engine Piston Installation..........................................................................................................................................................................101 Specification, Cam Thrust Plate Fastener Torque.....................................................................................................................................................102 Engine Oil Pump Installation........................................................................................................................................................................102 Specification, Oil Pump Bolt Torque.................................................................................................................................................................103 Engine Gears, Installation.........................................................................................................................................................................104 Specification, Balance Shaft Gear Bolt Torque.......................................................................................................................................................104 Specification, Camshaft Gear Bolt Torque............................................................................................................................................................105 Gear / Stator Housing Seal Replacement..............................................................................................................................................................105 Engine Stator Gear Cover Seal(s) Installation.......................................................................................................................................................106 Engine Stator Installation..........................................................................................................................................................................108 Engine Oil Priming..................................................................................................................................................................................109 Flywheel / Stator Installation..........................................................................................................................................................................110 Engine Flywheel / Stator Installation...................................................................................................................................................................110 Cylinder Head Reassembly................................................................................................................................................................................111 Engine Head Assembly....................................................................................................................................................................................111 TROUBLESHOOTING.............................................................................................................................................................................................113 Engine..................................................................................................................................................................................................113 Engine Troubleshooting..................................................................................................................................................................................113 Cooling System..........................................................................................................................................................................................114 Engine Cooling System Troubleshooting...................................................................................................................................................................114 800 EFI Exhaust System (DELUXE).............................................................................................................................................................................115 Dual Exhaust Layout.....................................................................................................................................................................................115 Exhaust Breakdown, Sportsman 800 EFI....................................................................................................................................................................115 Exhaust, Dual 800 EFI...................................................................................................................................................................................115 CH 4 - FUEL INJECTION...........................................................................................................................................................................................117 GENERAL INFORMATION.........................................................................................................................................................................................118 Special Tools...........................................................................................................................................................................................118 Fuel Injection, Special Tools...........................................................................................................................................................................118 Service Notes...........................................................................................................................................................................................119 Fuel Injection, Service Notes...........................................................................................................................................................................119 EFI System Exploded View................................................................................................................................................................................120 Fuel Injection, Exploded View........................................................................................................................................................................... 0 EFI System Component Locations..........................................................................................................................................................................121 Fuel Injection, Component Locations.....................................................................................................................................................................121 Fuel Tank Assembly......................................................................................................................................................................................122 Fuel Tank Location...................................................................................................................................................................................... 0 Fuel Lines - Quick Connect..............................................................................................................................................................................122 ELECTRONIC FUEL INJECTION...................................................................................................................................................................................123 Principal Components....................................................................................................................................................................................123 EFI Operation Overview..................................................................................................................................................................................123 EFI Operation Overview..................................................................................................................................................................................123 Initial Priming / Starting Procedure....................................................................................................................................................................123 EFI Priming / Starting Procedure........................................................................................................................................................................123 ELECTRONIC CONTROL UNIT (ECU)...............................................................................................................................................................................124 Operation Overview......................................................................................................................................................................................124 Electronic Control Unit (ECU)...........................................................................................................................................................................124 ECU Service.............................................................................................................................................................................................124 ECU Replacement.........................................................................................................................................................................................124 FUEL PUMP...................................................................................................................................................................................................125 Operation Overview......................................................................................................................................................................................125 Fuel Pump / Tank Assembly...............................................................................................................................................................................125 Fuel Pump Test..........................................................................................................................................................................................125 Fuel Pump / Tank Assembly Replacement...................................................................................................................................................................126 FUEL PRESSURE REGULATOR.....................................................................................................................................................................................128 Operation Overview......................................................................................................................................................................................128 Fuel Pressure Regulator.................................................................................................................................................................................128 Fuel Pressure Regulator Test............................................................................................................................................................................128 Fuel Pressure Regulator Replacement.....................................................................................................................................................................128 FUEL FILTERS................................................................................................................................................................................................128 General Information.....................................................................................................................................................................................128 Fuel Filter.............................................................................................................................................................................................128 Fuel Filter Service.....................................................................................................................................................................................128 Fuel Filter Replacement.................................................................................................................................................................................128 FUEL INJECTORS..............................................................................................................................................................................................129 Operation Overview......................................................................................................................................................................................129 Fuel Injector...........................................................................................................................................................................................129 Fuel Injector Service...................................................................................................................................................................................129 Fuel Injector Replacement...............................................................................................................................................................................129 CRANKSHAFT POSITION SENSOR (CPS)............................................................................................................................................................................130 Operation Overview......................................................................................................................................................................................130 Crankshaft Position Sensor (CPS)........................................................................................................................................................................130 Crankshaft Position Sensor Test.........................................................................................................................................................................130 Crankshaft Position Sensor (CPS) Replacement............................................................................................................................................................130 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)........................................................................................................................................................131 Operation Overview......................................................................................................................................................................................131 Temperature / Barometric Air Pressure Sensor (T-Bap)....................................................................................................................................................131 Temperature and Barometric Air Pressure Sensor Test.....................................................................................................................................................131 Temperature and Barometric Air Pressure Sensor Replacement..............................................................................................................................................131 THROTTLE POSITION SENSOR (TPS)..............................................................................................................................................................................131 Operation Overview......................................................................................................................................................................................131 Throttle Position Sensor................................................................................................................................................................................131 Throttle Position Sensor Replacement....................................................................................................................................................................131 Throttle Position Sensor Replacement....................................................................................................................................................................131 Throttle Position Sensor Test...........................................................................................................................................................................132 Throttle Position Sensor Initialization.................................................................................................................................................................132 Throttle Position Sensor Initialization.................................................................................................................................................................132 ENGINE TEMPERATURE SENSOR...................................................................................................................................................................................134 Operation Overview......................................................................................................................................................................................134 Engine Temperature Sensor...............................................................................................................................................................................134 Engine Temperature Sensor Test..........................................................................................................................................................................134 Engine Temperature Sensor Test..........................................................................................................................................................................134 Engine Temperature Sensor Replacement...................................................................................................................................................................134 Engine Temperature Sensor Replacement...................................................................................................................................................................134 TROUBLESHOOTING.............................................................................................................................................................................................135 Diagnostics Using “Blink Codes”.........................................................................................................................................................................135 Engine Diagnostic Codes.................................................................................................................................................................................135 EFI Troubleshooting.....................................................................................................................................................................................136 EFI Troubleshooting.....................................................................................................................................................................................136 EFI CIRCUIT - Power On..................................................................................................................................................................................137 Fuel System, EFI Circuit Diagrams....................................................................................................................................................................... 0 Troubleshooting, EFI Circuit Diagrams................................................................................................................................................................... 0 EFI CIRCUIT - Crank Position Sensor.....................................................................................................................................................................137 EFI CIRCUIT - Fuel Pump.................................................................................................................................................................................138 EFI CIRCUIT - Throttle Position Sensor..................................................................................................................................................................138 EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor..............................................................................................................................................139 EFI CIRCUIT - Engine Temperature........................................................................................................................................................................139 EFI CIRCUIT - Malfunction Indicator Light...............................................................................................................................................................140 CH 5 - BODY/STEERING/SUSPENSION.................................................................................................................................................................................141 GENERAL INFORMATION.........................................................................................................................................................................................142 Torque Specifications...................................................................................................................................................................................142 Specifications, Body and Steering Torque Values.........................................................................................................................................................142 Body and Steering Torque Values.........................................................................................................................................................................142 Steering Torque Values..................................................................................................................................................................................142 Special Tools ..........................................................................................................................................................................................142 Special Tools, Body & Steering..........................................................................................................................................................................142 Decal Replacement.......................................................................................................................................................................................142 Decal Replacement.......................................................................................................................................................................................142 Plastic Insert Removal / Installation...................................................................................................................................................................143 Plastic Inserts.........................................................................................................................................................................................143 BODY........................................................................................................................................................................................................144 Side Panel Removal......................................................................................................................................................................................144 Side Panel Removal......................................................................................................................................................................................144 Front Cover Removal / Installation......................................................................................................................................................................144 Front Cover Removal / Installation......................................................................................................................................................................144 Foot Well Removal / Installation........................................................................................................................................................................145 Foot Well Removal / Installation........................................................................................................................................................................145 X2 Foot Well Removal / Installation.....................................................................................................................................................................145 Foot Well Removal / Installation........................................................................................................................................................................145 Front Storage Removal...................................................................................................................................................................................146 Front Storage Removal...................................................................................................................................................................................146 Front Storage Installation..............................................................................................................................................................................148 Front Storage Installation..............................................................................................................................................................................148 Sportsman Rear Rack Removal / Installation..............................................................................................................................................................148 Rear Rack Removal / Installation........................................................................................................................................................................148 Front Cab/Fender Removal/Installation...................................................................................................................................................................149 Front Cab Removal / Installation........................................................................................................................................................................149 Sportsman Rear Cab / Fender Removal / Installation......................................................................................................................................................150 Rear Cab Removal / Installation.........................................................................................................................................................................150 X2 Rear Quarter Panel Removal / Installation............................................................................................................................................................150 Sportsman Rear Storage Removal / Installation...........................................................................................................................................................151 Rear Storage Removal / Installation.....................................................................................................................................................................151 Radiator Screen Removal.................................................................................................................................................................................151 Radiator Screen Removal.................................................................................................................................................................................151 Sportsman Body Assembly Exploded View...................................................................................................................................................................152 Body Assembly Exploded View............................................................................................................................................................................. 0 X2 Body Assembly Exploded View..........................................................................................................................................................................153 Body Assembly Exploded View............................................................................................................................................................................. 0 Body / Rack Exploded Views..............................................................................................................................................................................154 Body Rack Exploded View................................................................................................................................................................................. 0 Headlight Pod Exploded View.............................................................................................................................................................................155 Headlight Pod Exploded View.............................................................................................................................................................................155 STEERING....................................................................................................................................................................................................156 Handlebar Block Installation Procedure..................................................................................................................................................................156 Handlebar Block Installation Procedure..................................................................................................................................................................156 Steering / A-arm Exploded View..........................................................................................................................................................................157 Steering A-Arm Exploded View............................................................................................................................................................................157 A-Arm Replacement.......................................................................................................................................................................................158 A-Arm Replacement.......................................................................................................................................................................................158 Ball Joint Replacement..................................................................................................................................................................................159 Ball Joint Replacement, Front...........................................................................................................................................................................159 Steering Post Removal...................................................................................................................................................................................160 Steering Post Removal............................................................................................................................................................................... 0 Steering Post Assembly..................................................................................................................................................................................160 Steering Post Assembly..................................................................................................................................................................................160 SUSPENSION..................................................................................................................................................................................................160 Front Strut Cartridge Replacement.......................................................................................................................................................................160 Strut Cartridge Replacement, Front......................................................................................................................................................................160 Strut Assembly..........................................................................................................................................................................................161 Strut Assembly......................................................................................................................................................................................... 0 Sportsman Rear Suspension Assembly......................................................................................................................................................................162 Rear Suspension Assembly................................................................................................................................................................................ 0 X2 Rear Suspension Exploded View........................................................................................................................................................................163 Rear Suspension Assembly................................................................................................................................................................................ 0 X2 Torsion Bar Exploded View............................................................................................................................................................................164 X2 CARGO BOX................................................................................................................................................................................................165 Exploded View...........................................................................................................................................................................................165 Removal / Installation..................................................................................................................................................................................166 Cargo Box, Removal and Installation.....................................................................................................................................................................166 X2 SEAT assembly............................................................................................................................................................................................168 Exploded Views..........................................................................................................................................................................................168 X2 Seat Operation - Configuring Cargo Box For Passenger Riding..........................................................................................................................................169 Passenger Seat, Operation...............................................................................................................................................................................169 Driver Seat Backrest Removal / Installation.............................................................................................................................................................170 X2, Seat Disassembly....................................................................................................................................................................................170 Passenger Seat Backrest Removal / Installation..........................................................................................................................................................170 CH 6 - CLUTCH SYSTEM............................................................................................................................................................................................171 SPECIAL TOOLS AND SPECIFICATIONS............................................................................................................................................................................172 Special Tools...........................................................................................................................................................................................172 PVT Special Tools.......................................................................................................................................................................................172 Component Fastener Torques..............................................................................................................................................................................172 PVT Torque Specs........................................................................................................................................................................................172 Specification, PVT Component Torque Table...............................................................................................................................................................172 PVT EXPLODED VIEWS..........................................................................................................................................................................................173 PVT Sealing And Ducting Components......................................................................................................................................................................173 PVT Ducting............................................................................................................................................................................................. 0 Drive Clutch Exploded Views (Standard and Deluxe).......................................................................................................................................................173 PVT, Drive Clutch Exploded View......................................................................................................................................................................... 0 Driven Clutch Exploded Views (Standard and Deluxe)......................................................................................................................................................174 EBS Exploded View....................................................................................................................................................................................... 0 Engine Braking System (EBS) Exploded View...............................................................................................................................................................175 EBS Exploded View....................................................................................................................................................................................... 0 PVT SYSTEM..................................................................................................................................................................................................176 PVT Operation Overview..................................................................................................................................................................................176 PVT Operation...........................................................................................................................................................................................176 Drive Clutch Operation..................................................................................................................................................................................176 PVT Drive Clutch Operation..............................................................................................................................................................................176 Drive Clutch, Operation.................................................................................................................................................................................176 Driven Clutch Operation.................................................................................................................................................................................176 PVT Driven Clutch Operation.............................................................................................................................................................................176 Driven Clutch, Operation................................................................................................................................................................................176 EBS Clutch Operation....................................................................................................................................................................................177 PVT, EBS Clutch Operation...............................................................................................................................................................................177 EBS, Driven Clutch Operation............................................................................................................................................................................177 PVT Maintenance / Inspection............................................................................................................................................................................177 PVT Maintenance / Inspection...........................................................................................................................................................................177 Drive Clutch Spring.....................................................................................................................................................................................178 PVT Drive Clutch Specifications.........................................................................................................................................................................178 Drive Clutch Springs....................................................................................................................................................................................178 Optional Shift Weights..................................................................................................................................................................................179 PVT Drive Clutch Shift Weights.........................................................................................................................................................................179 Drive Clutch Weights....................................................................................................................................................................................179 PVT Drying..............................................................................................................................................................................................180 PVT Drying..............................................................................................................................................................................................180 PVT Disassembly ........................................................................................................................................................................................180 PVT Disassembly.........................................................................................................................................................................................180 PVT Installation........................................................................................................................................................................................181 PVT Assembly............................................................................................................................................................................................181 Drive Belt Removal / Inspection.........................................................................................................................................................................182 PVT, Drive Belt Removal/Inspection......................................................................................................................................................................182 Drive Belt, Removal/Inspection..........................................................................................................................................................................182 Specification, PVT Drive Belt Width.................................................................................................................................................................183 Specification, PVT Center-to-Center Distance........................................................................................................................................................183 DRIVE BELT INSTALLATION.................................................................................................................................................................................183 PVT, Drive Belt Installation............................................................................................................................................................................183 Drive Belt, Installation................................................................................................................................................................................183 Clutch Alignment........................................................................................................................................................................................184 PVT, Clutch Alignment...................................................................................................................................................................................184 Clutch Alignment........................................................................................................................................................................................184 Clutch Offset...........................................................................................................................................................................................184 PVT, Clutch Offset......................................................................................................................................................................................184 Clutch Offset...........................................................................................................................................................................................184 EBS DRIVE CLUTCH SERVICE....................................................................................................................................................................................185 EBS Drive Clutch Service....................................................................................................................................................................................185 Drive Clutch Disassembly................................................................................................................................................................................185 PVT, Drive Clutch Disassembly...........................................................................................................................................................................185 Spider Removal..........................................................................................................................................................................................185 PVT, Drive Clutch Spider Removal........................................................................................................................................................................185 Button To Tower Clearance Inspection....................................................................................................................................................................187 Shift Weight Inspection.................................................................................................................................................................................187 PVT, Button to Tower Clearance..........................................................................................................................................................................187 Drive Clutch Inspection.................................................................................................................................................................................187 Moveable Sheave Bushing Inspection......................................................................................................................................................................188 PVT, Moveable Sheave Inspection.........................................................................................................................................................................188 Drive Clutch Bushing Service............................................................................................................................................................................188 PVT, EBS Drive Clutch Bushing Service...................................................................................................................................................................188 PVT, EBS Drive Clutch Cover Bushing Remove/Install......................................................................................................................................................190 One-Way Clutch Inspection (Drive Clutch)................................................................................................................................................................190 Drive Clutch Reassembly.................................................................................................................................................................................190 PVT, Drive Clutch Reassembly............................................................................................................................................................................190 EBS DRIVEN CLUTCH SERVICE...................................................................................................................................................................................192 EBS Driven Clutch Service...................................................................................................................................................................................192 Driven Clutch Disassembly ..............................................................................................................................................................................192 PVT, Driven Clutch Disassembly..........................................................................................................................................................................192 DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION.............................................................................................................................................................194 PVT, Driven Clutch Bushing Service......................................................................................................................................................................194 EBS DRIVEN CLUTCH REASSEMBLY............................................................................................................................................................................195 PVT, Driven Clutch Reassembly...........................................................................................................................................................................195 standard drive clutch.......................................................................................................................................................................................198 Drive Clutch, Standard Service..............................................................................................................................................................................198 Drive Clutch Disassembly................................................................................................................................................................................198 PVT, Drive Clutch Disassembly...........................................................................................................................................................................198 Spider Removal..........................................................................................................................................................................................199 PVT, Drive Clutch Spider Removal........................................................................................................................................................................199 Button To Tower Clearance Inspection....................................................................................................................................................................200 Shift Weight Inspection.................................................................................................................................................................................200 PVT, Button to Tower Clearance..........................................................................................................................................................................200 Sheave / Bushing Inspection.............................................................................................................................................................................201 PVT, Moveable Sheave Inspection.........................................................................................................................................................................201 Drive Clutch Bushing Service............................................................................................................................................................................201 PVT, EBS Drive Clutch Bushing Service...................................................................................................................................................................201 PVT, EBS Drive Clutch Cover Bushing Remove/Install......................................................................................................................................................202 Drive Clutch Reassembly.................................................................................................................................................................................202 PVT, Drive Clutch Reassembly............................................................................................................................................................................202 standard driven clutch......................................................................................................................................................................................204 Driven Clutch, Standard Service.............................................................................................................................................................................204 Disassembly.............................................................................................................................................................................................204 Inspection..............................................................................................................................................................................................204 Assembly................................................................................................................................................................................................205 PVT TROUBLESHOOTING.........................................................................................................................................................................................206 Clutch, Troubleshooting.....................................................................................................................................................................................206 Overheating.............................................................................................................................................................................................206 PVT Overheating Chart...................................................................................................................................................................................206 Problem, Cause and Remedy Chart.........................................................................................................................................................................207 PVT Troubleshooting Chart...............................................................................................................................................................................207 CH 7 - FINAL DRIVE..............................................................................................................................................................................................209 SPECIFICATIONS..............................................................................................................................................................................................210 Torque Table............................................................................................................................................................................................210 Specifications, Final Drive Torque Values...............................................................................................................................................................210 Final Drive Torque Specifications.......................................................................................................................................................................210 Special Tools...........................................................................................................................................................................................210 Special Tools, Final Drive..............................................................................................................................................................................210 Gearcase Fluid / Capacity...............................................................................................................................................................................210 Specifications, Front Gearcase Lubrication Type/Capacity................................................................................................................................................210 Gearcase, Front Capacity and Fluid Type.................................................................................................................................................................210 FRONT DRIVE AXLE............................................................................................................................................................................................210 Removal.................................................................................................................................................................................................210 Front Drive Axle Removal................................................................................................................................................................................210 Installation............................................................................................................................................................................................212 Front Drive Axle Installation...........................................................................................................................................................................212 FRONT DRIVE SHAFT (CV) BOOT.................................................................................................................................................................................212 Inspection..............................................................................................................................................................................................212 Drive Shaft Boot Inspection.............................................................................................................................................................................212 Replacement.............................................................................................................................................................................................212 CV Boot, Replacement....................................................................................................................................................................................212 FRONT HUB...................................................................................................................................................................................................214 Disassembly.............................................................................................................................................................................................214 Front Hub, Disassembly..................................................................................................................................................................................214 Assembly................................................................................................................................................................................................214 Front Hub, Assembly.....................................................................................................................................................................................214 PROP SHAFT - FRONT OR REAR..................................................................................................................................................................................215 Removal and Installation................................................................................................................................................................................215 Propshaft, Removal......................................................................................................................................................................................215 U-JOINT.....................................................................................................................................................................................................215 U-joint, Disassembly and Assembly...........................................................................................................................................................................215 Disassembly.............................................................................................................................................................................................215 Assembly................................................................................................................................................................................................216 DRIVE AXLE EXPLODED VIEWS...................................................................................................................................................................................218 Drive Shafts and Propshafts.............................................................................................................................................................................218 FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MoDELS).....................................................................................................................................................219 Front Gearcase, Operation...................................................................................................................................................................................219 Exploded View (Standard Models).........................................................................................................................................................................219 Front Gearcase, Exploded View...........................................................................................................................................................................219 Operation...............................................................................................................................................................................................220 Gearcase Removal........................................................................................................................................................................................220 Front Gearcase, Removal.................................................................................................................................................................................220 Disassembly / Inspection................................................................................................................................................................................221 Front Gearcase, Disassembly / Inspection................................................................................................................................................................221 Front Gearcase Coil Resistance......................................................................................................................................................................222 Reassembly / Inspection.................................................................................................................................................................................225 Front Gearcase, Reassembly / Inspection.................................................................................................................................................................225 Front Gearcase - Back Lash Pad Adjustment........................................................................................................................................................... 0 Setting Ring Gear Backlash..............................................................................................................................................................................226 Front Gearcase Diagnosis................................................................................................................................................................................227 Front Gearcase, Diagnoses...............................................................................................................................................................................227 Gearcase Installation...................................................................................................................................................................................228 Front Gearcase, Installation............................................................................................................................................................................228 FRONT GEARCASE - Active descent control (deluxe models).....................................................................................................................................................229 ADC Gearcase Exploded View (Deluxe Models)..............................................................................................................................................................229 Front Gearcase, Active Descent Control Exploded View....................................................................................................................................................229 Operation...............................................................................................................................................................................................230 Active Descent Control Gearcase.........................................................................................................................................................................230 ADC Coil Testing........................................................................................................................................................................................231 ADC Differential Hydraulic Circuit Bleeding.............................................................................................................................................................231 Disassembly / Inspection................................................................................................................................................................................231 ADC Gearcase, Disassembly / Inspection..................................................................................................................................................................231 Front Gearcase Coil Resistance......................................................................................................................................................................232 ADC Gearcase Piston Replacement Procedure...............................................................................................................................................................235 ADC Gearcase Piston Service.............................................................................................................................................................................235 Assembly................................................................................................................................................................................................237 Front Gearcase, Reassembly..............................................................................................................................................................................237 REAR HUB....................................................................................................................................................................................................240 Removal.................................................................................................................................................................................................240 Disassembly.............................................................................................................................................................................................241 Assembly................................................................................................................................................................................................242 Installation............................................................................................................................................................................................242 REAR DRIVE (CV) SHAFT.......................................................................................................................................................................................243 Removal.................................................................................................................................................................................................243 Service.................................................................................................................................................................................................244 CV Boot Replacement.....................................................................................................................................................................................245 INSTALLATION............................................................................................................................................................................................246 Drive Shaft and CV Joint Handling Tips..................................................................................................................................................................247 REAR GEARCASE...............................................................................................................................................................................................247 Removal.................................................................................................................................................................................................247 Rear Gearcase, Removal..................................................................................................................................................................................247 Disassembly and Inspection..............................................................................................................................................................................247 Rear Gearcase, Disassembly..............................................................................................................................................................................247 Reassembly..............................................................................................................................................................................................249 Rear Gearcase, Assembly.................................................................................................................................................................................249 Installation ...........................................................................................................................................................................................250 Rear Gearcase, Installation.............................................................................................................................................................................250 Rear Gearcase Exploded View.............................................................................................................................................................................251 Rear Gearcase, Exploded View............................................................................................................................................................................ 0 sPORTSMAN 8.3-8.18..........................................................................................................................................................................................253 sPORTSMAN X2 8.19-8.38......................................................................................................................................................................................253 CH 8 - TRANSMISSION / SPORTSMAN.................................................................................................................................................................................255 TRANSMISSION EXPLODED VIEW..................................................................................................................................................................................256 Sportsman Transmission .................................................................................................................................................................................256 Transmission Exploded View..............................................................................................................................................................................257 SPECIFICIATONS..............................................................................................................................................................................................258 Torque Specifications...................................................................................................................................................................................258 Lubricant / Capacity....................................................................................................................................................................................258 TRANSMISSION SERVICE........................................................................................................................................................................................258 Transmission Removal....................................................................................................................................................................................258 Transmission Gear Selector Removal......................................................................................................................................................................258 Transmission Removal....................................................................................................................................................................................258 Disassembly.............................................................................................................................................................................................259 Transmission Disassembly................................................................................................................................................................................259 Assembly................................................................................................................................................................................................264 Transmission Assembly...................................................................................................................................................................................264 Transmission Installation...............................................................................................................................................................................269 Transmission Installation...............................................................................................................................................................................269 Troubleshooting.........................................................................................................................................................................................270 Transmission Troubleshooting............................................................................................................................................................................270 CH 8 - TRANSMISSION / X2........................................................................................................................................................................................271 Transmission................................................................................................................................................................................................272 TRANSMISSION EXPLODED VIEWS.............................................................................................................................................................................272 X2 Transmission Exploded View.......................................................................................................................................................................272 Transmission, Exploded View......................................................................................................................................................................... 0 X2 Mounting Exploded View...........................................................................................................................................................................274 Transmission Mounts, Exploded View.................................................................................................................................................................. 0 sPECIFICATIONS..........................................................................................................................................................................................275 Torque Specifications...............................................................................................................................................................................275 Special Tools.......................................................................................................................................................................................275 Transmission, Special Tools.........................................................................................................................................................................275 Lubrication.........................................................................................................................................................................................275 TRANSMISSION SERVICE....................................................................................................................................................................................275 Gear Selector Removal...............................................................................................................................................................................275 Transmission Removal................................................................................................................................................................................275 Transmission, Removal...............................................................................................................................................................................275 Transmission Installation...........................................................................................................................................................................277 Transmission, Install...............................................................................................................................................................................277 Troubleshooting Checklist...........................................................................................................................................................................278 Transmission Disassembly............................................................................................................................................................................279 Transmission, Disassembly...........................................................................................................................................................................279 Transmission assembly...............................................................................................................................................................................284 Transmission, Reassembly............................................................................................................................................................................284 Transmission front output shaft backlash procedure..................................................................................................................................................285 Transmission, Output Shaft Backlash Procedure.......................................................................................................................................................285 Specification, Transmission Silent Chain Length.................................................................................................................................................287 CH 9 - BRAKES...................................................................................................................................................................................................291 SPECIFICATIONS..............................................................................................................................................................................................292 Torque Table............................................................................................................................................................................................292 Brake, Torque Specifications............................................................................................................................................................................292 Specifications, Brake Component Torque Values...........................................................................................................................................................292 Component Service Limits................................................................................................................................................................................292 Specifications, Brake Component Service Limits..........................................................................................................................................................292 BRAKE SYSTEM Exploded Views.................................................................................................................................................................................293 Brake System Exploded Views.................................................................................................................................................................................293 X2 System Component Exploded View.......................................................................................................................................................................293 Brake System Components, X2............................................................................................................................................................................. 0 Sportsman System Component Exploded View................................................................................................................................................................294 Brake System Components, Std, Sportsman................................................................................................................................................................. 0 BRAKE CALIPER EXPLODED VIEWS................................................................................................................................................................................295 Brake Caliper Exploded View.................................................................................................................................................................................295 Sportsman and X2 Front Caliper Assembly.................................................................................................................................................................295 X2 Rear Caliper Assembly................................................................................................................................................................................295 Sportsman Rear Caliper Assembly.........................................................................................................................................................................296 HYDRAULIC BRAKE SYSTEM......................................................................................................................................................................................296 Hydraulic Brake System Operation Overview...................................................................................................................................................................296 Operation Overview......................................................................................................................................................................................296 Brakes, Operation Overview..............................................................................................................................................................................296 Brake Noise Troubleshooting.............................................................................................................................................................................297 Brake Noise Troubleshooting.............................................................................................................................................................................297 Brake Bleeding / Fluid Change...........................................................................................................................................................................297 Brake Bleeding..........................................................................................................................................................................................297 FRONT MASTER CYLINDER.......................................................................................................................................................................................299 Brake, Master Cylinder Removal.............................................................................................................................................................................299 Removal.................................................................................................................................................................................................299 Installation............................................................................................................................................................................................299 FRONT BRAKES................................................................................................................................................................................................300 Brake Pad, Removal and Installation.........................................................................................................................................................................300 Pad Removal.............................................................................................................................................................................................300 Assembly................................................................................................................................................................................................301 Brake Burnishing Procedure..............................................................................................................................................................................302 Brake Burnishing Procedure..............................................................................................................................................................................302 FRONT BRAKE DISC............................................................................................................................................................................................302 Brake Disc, Front...........................................................................................................................................................................................302 Inspection..............................................................................................................................................................................................302 Removal / Replacement...................................................................................................................................................................................303 FRONT CALIPER...............................................................................................................................................................................................304 Brake Caliper, Front........................................................................................................................................................................................304 Removal.................................................................................................................................................................................................304 Inspection..............................................................................................................................................................................................305 Reassembly..............................................................................................................................................................................................305 Installation............................................................................................................................................................................................306 REAR BRAKE PAD..............................................................................................................................................................................................307 Brake Pad, Rear.............................................................................................................................................................................................307 X2 Pad Removal..........................................................................................................................................................................................307 X2 Pad Installation.....................................................................................................................................................................................308 Sportsman Rear Pad Removal..............................................................................................................................................................................309 Brake Pad Removal, Rear.................................................................................................................................................................................309 Specification, Brake Pad Thickness..................................................................................................................................................................309 Sportsman Rear Pad Installation.........................................................................................................................................................................310 Brake Pad Install, Rear.................................................................................................................................................................................310 Brake Burnishing Procedure..............................................................................................................................................................................310 X2 REAR CALIPER.............................................................................................................................................................................................311 Brake Caliper Removal, Rear.................................................................................................................................................................................311 Removal.................................................................................................................................................................................................311 Inspection..............................................................................................................................................................................................312 Reassembly..............................................................................................................................................................................................312 Sportsman REAR CALIPER......................................................................................................................................................................................313 Removal and Inspection..................................................................................................................................................................................313 Brake Caliper Removal, Rear.............................................................................................................................................................................313 Assembly................................................................................................................................................................................................314 Brake Caliper, Assembly.................................................................................................................................................................................314 REAR BRAKE DISC.............................................................................................................................................................................................315 Brake Disc, Inspection......................................................................................................................................................................................315 Inspection..............................................................................................................................................................................................315 Specification, Brake Disc Thickness.................................................................................................................................................................315 Specification, Brake Disc Service Limit.............................................................................................................................................................315 REAR MASTER CYLINDER........................................................................................................................................................................................316 Brake, Rear Auxiliary Master Cylinder.......................................................................................................................................................................316 X2 Exploded View........................................................................................................................................................................................316 Rear Master Cylinder, Exploded View..................................................................................................................................................................... 0 Overview................................................................................................................................................................................................317 X2 Rear Master Cylinder Removal and Installation........................................................................................................................................................317 Sportsman Rear Master Cylinder Removal / Installation...................................................................................................................................................318 Brake, Rear Auxiliary Brake.............................................................................................................................................................................318 Pedal Removal and Installation..........................................................................................................................................................................319 TROUBLESHOOTING.............................................................................................................................................................................................319 Brakes, Troubleshooting.....................................................................................................................................................................................319 Brakes Squeal...........................................................................................................................................................................................319 Poor Brake Performance..................................................................................................................................................................................319 Lever Vibration.........................................................................................................................................................................................319 Caliper Overheats (Brakes Drag).........................................................................................................................................................................319 Brakes Lock.............................................................................................................................................................................................319 CH 10 - ELECTRICAL..............................................................................................................................................................................................321 INSTRUMENT CLUSTER .........................................................................................................................................................................................323 Instrument Cluster (Speedometer) Overview...................................................................................................................................................................323 Overview................................................................................................................................................................................................323 Speedometer, Funtions Overview..........................................................................................................................................................................323 Instrument Cluster Diagnostic Mode......................................................................................................................................................................324 Diagnostic Mode, Instrument Cluster.....................................................................................................................................................................324 Clock, Setting Time of Day..............................................................................................................................................................................324 Setting A New Service Interval..........................................................................................................................................................................326 Instrument Cluster, Setting New Service Interval........................................................................................................................................................326 Service Intervals, Speedometer..........................................................................................................................................................................326 EFI Diagnostic Mode.....................................................................................................................................................................................327 EFI Diagnostic Mode Using Instrument Cluster............................................................................................................................................................327 Diagnostic Mode, EFI System.............................................................................................................................................................................327 Diagnostic Codes........................................................................................................................................................................................328 Speedometer Removal.....................................................................................................................................................................................328 Speedometer Removal.....................................................................................................................................................................................328 Speedometer Installation................................................................................................................................................................................329 Speedometer Installation................................................................................................................................................................................329 SPEEDOMETER TROUBLESHOOTING.................................................................................................................................................................................330 Test 1 - No All Wheel Drive.............................................................................................................................................................................330 Speedometer Troubleshooting Tests....................................................................................................................................................................... 0 TEST 2 - No Display / TEST 3 - No Reverse Speed Limit...................................................................................................................................................331 TEST 4 - No AWD Hub Safety Limiter......................................................................................................................................................................332 TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor .................................................................................................................................................333 TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch...................................................................................................................................................334 ACTIVE DESCENT CONTROL (ADC) COIL...........................................................................................................................................................................335 Active Descent Control (ADC) Coil...........................................................................................................................................................................335 Operation Overview......................................................................................................................................................................................335 Diagnosing System Failures..............................................................................................................................................................................335 ALL WHEEL DRIVE (AWD) COIL..................................................................................................................................................................................335 All Wheel Drive (AWD) Coil..................................................................................................................................................................................335 Operation Overview......................................................................................................................................................................................335 Diagnosing System Failures..............................................................................................................................................................................335 COOLING SYSTEM COMPONENTS...................................................................................................................................................................................336 Fan Control Circuit Operation / Testing.................................................................................................................................................................336 Fan Control Circuit Operation...........................................................................................................................................................................336 Fan Control Circuit Bypass Test.........................................................................................................................................................................336 Fan Control Circuit Operation / Testing.................................................................................................................................................................336 Coolant Temperature Sensor..............................................................................................................................................................................336 Specification, Coolant Sensor Resistance................................................................................................................................................................336 Fan Motor Current Draw..................................................................................................................................................................................337 Fan Motor Current Draw..................................................................................................................................................................................337 GEAR POSITION INDICATOR SWITCH..............................................................................................................................................................................337 Test Diagram............................................................................................................................................................................................337 Gear Position Indicator Switch Test..................................................................................................................................................................... 0 ELECTRONIC THROTTLE CONTROL (ETC) SWITCH....................................................................................................................................................................338 ETC Switch Operation....................................................................................................................................................................................338 ETC Switch Operation....................................................................................................................................................................................338 ETC Operation Test......................................................................................................................................................................................338 ETC Operation Test......................................................................................................................................................................................338 IGNITION SYSTEM.............................................................................................................................................................................................339 Flywheel Identification.................................................................................................................................................................................339 Flywheel ID.............................................................................................................................................................................................339 EFI - DC/CDI Ignition Overview..........................................................................................................................................................................339 Ignition Curve..........................................................................................................................................................................................339 Alternator/Ignition Components - 700/800 EFI............................................................................................................................................................340 Alternator / Ignition Components........................................................................................................................................................................ 0 Crankshaft Position Sensor Gap..........................................................................................................................................................................341 Crank Position Sensor Gap...............................................................................................................................................................................341 Ignition System Troubleshooting.........................................................................................................................................................................341 Ignition System Troubleshooting.........................................................................................................................................................................341 CHARGING SYSTEM.............................................................................................................................................................................................341 Current Draw - Key Off..................................................................................................................................................................................341 Current Draw - Key Off Test............................................................................................................................................................................341 Charging System “Break Even” Test.......................................................................................................................................................................342 Charging System - Break Even Test.......................................................................................................................................................................342 Alternator Output Test..................................................................................................................................................................................342 Alternator Output Test..................................................................................................................................................................................342 Charging System Testing Flow Chart......................................................................................................................................................................344 Charging System Flow Chart.............................................................................................................................................................................. 0 RELAYS......................................................................................................................................................................................................345 Operation...............................................................................................................................................................................................345 Relays..................................................................................................................................................................................................345 FUSES/Circuit Breaker.......................................................................................................................................................................................346 Operation...............................................................................................................................................................................................346 Fuses...................................................................................................................................................................................................346 Circuit Breaker.........................................................................................................................................................................................346 LIGHTING....................................................................................................................................................................................................346 High Beam Headlight Bulb Replacement....................................................................................................................................................................346 High Beam Bulb Replacement..............................................................................................................................................................................346 Headlight Housing Replacement...........................................................................................................................................................................347 Headlight Housing Replacement...........................................................................................................................................................................347 High Beam Headlight Adjustment .........................................................................................................................................................................348 High Beam Headlight Adjustment..........................................................................................................................................................................348 Lower Headlamp Removal / Installation...................................................................................................................................................................348 Lower Headlamp Removal.................................................................................................................................................................................348 Lower Headlamp Housing Removal......................................................................................................................................................................349 Low Beam Headlight Adjustment...........................................................................................................................................................................349 Low Beam Headlight Adjustment...........................................................................................................................................................................349 Headlamp Switch Test....................................................................................................................................................................................349 Headlamp Switch Test....................................................................................................................................................................................349 Sportsman Work Light Switch (Deluxe)....................................................................................................................................................................350 Work Light Switch.......................................................................................................................................................................................350 Sportsman Brake Light / Work Light (Deluxe) Replacement.................................................................................................................................................350 Brake Light / Work Light Switch Replacement.............................................................................................................................................................350 X2 BRAKE LIGHT / WORK LIGHT (Deluxe) REPLACEMENT........................................................................................................................................................351 Brake Light / Work Light Switch Replacement.............................................................................................................................................................351 Brake Light Switch......................................................................................................................................................................................352 Brake Light Switch......................................................................................................................................................................................352 FUEL SENDER.................................................................................................................................................................................................353 Testing.................................................................................................................................................................................................353 Fuel Sender Test........................................................................................................................................................................................353 X2 DIFFERENTIAL System......................................................................................................................................................................................353 Solenoid Testing........................................................................................................................................................................................353 Solenoid, Differential..................................................................................................................................................................................353 Differential Solenoid...................................................................................................................................................................................353 Specification, Differential Solenoid Resistance.........................................................................................................................................................353 Solenoid Replacement....................................................................................................................................................................................353 Specification, Differential Solenoid Torque.........................................................................................................................................................353 Differential Relay Operation............................................................................................................................................................................354 Differential Relay Testing..............................................................................................................................................................................354 X2 SPEED SENSOR.............................................................................................................................................................................................354 Testing.................................................................................................................................................................................................354 Speed Sensor............................................................................................................................................................................................354 Special Tools, Speed Sensor.............................................................................................................................................................................354 Specification, Speed Sensor Bolt Torque................................................................................................................................................................354 Specification, Differential Solenoid Resistance.........................................................................................................................................................354 Replacement.............................................................................................................................................................................................354 Speedometer Sensor, Replacement.........................................................................................................................................................................354 Specification, Differential Solenoid Torque.........................................................................................................................................................354 ACCESSORY POWER.............................................................................................................................................................................................355 Wire Connections........................................................................................................................................................................................355 Accessory Power Wiring..................................................................................................................................................................................355 STARTER SYSTEM..............................................................................................................................................................................................356 700/800 Starter Lockout Overview and Diagnostic.........................................................................................................................................................356 Starter Interlock.......................................................................................................................................................................................356 Interlock, Starter, 700/800 EFI.........................................................................................................................................................................356 800 X2 Starter Lockout Overview and Diagnostic..........................................................................................................................................................357 Starter Interlock.......................................................................................................................................................................................357 Interlock, Starter, 800 X2 EFI..........................................................................................................................................................................357 Troubleshooting.........................................................................................................................................................................................358 Starter System, Troubleshooting.........................................................................................................................................................................358 Voltage Drop Test.......................................................................................................................................................................................358 Voltage Drop Test.......................................................................................................................................................................................358 Starter Motor Removal / Disassembly ....................................................................................................................................................................358 Starter Motor, Removal..................................................................................................................................................................................358 BRUSH INSPECTION / REPLACEMENT..........................................................................................................................................................................359 Starter Brush Inspection / Replacement..................................................................................................................................................................359 Armature Testing........................................................................................................................................................................................360 Starter Armature Testing................................................................................................................................................................................360 Starter Reassembly / Installation.......................................................................................................................................................................361 Starter Reassembly / Installation.......................................................................................................................................................................361 Starter Solenoid Bench Test.............................................................................................................................................................................361 Starter Drive...........................................................................................................................................................................................362 Starter Drive...........................................................................................................................................................................................362 Starter Exploded View...................................................................................................................................................................................363 Starter Assembly Exploded View.......................................................................................................................................................................... 0 STARTER SYSTEM TESTING FLOW CHART...........................................................................................................................................................................364 Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test....364 Starter System Flow Chart............................................................................................................................................................................... 0 BASIC WINCH WIRING- PRE-WIRED MODELS........................................................................................................................................................................365 Winch, Basic Wiring Diagram............................................................................................................................................................................. 0 BATTERY.....................................................................................................................................................................................................366 Battery Identification..................................................................................................................................................................................366 Battery Activation (Conventional).......................................................................................................................................................................366 Battery Activation, Conventional........................................................................................................................................................................366 Battery Terminals/Bolts.................................................................................................................................................................................367 Battery Terminals/Bolts.................................................................................................................................................................................367 Conventional Battery Inspection / Removal...............................................................................................................................................................367 Battery Removal / Inspection, Conventional..............................................................................................................................................................367 Conventional Battery Installation.......................................................................................................................................................................367 Conventional Battery Testing............................................................................................................................................................................368 Conventional Battery OCV - Open Circuit Voltage Test....................................................................................................................................................368 Conventional Battery Specific Gravity Test..............................................................................................................................................................368 Specific Gravity Test, Conventional Battery.............................................................................................................................................................368 Battery Load Test.......................................................................................................................................................................................369 Battery Load Test.......................................................................................................................................................................................369 Off Season Storage......................................................................................................................................................................................369 Battery Off Season Storage..............................................................................................................................................................................369 Charging Procedure......................................................................................................................................................................................369 Charging Procedure......................................................................................................................................................................................369 Low Maintenance Battery.................................................................................................................................................................................370 Low Maintenance Battery Info............................................................................................................................................................................370 Low Maintenance Battery Charging........................................................................................................................................................................370 Low Maintenance Battery Charging........................................................................................................................................................................370 Low Maintenance Battery Inspection / Removal............................................................................................................................................................371 Battery Inspection / Removal, Low Maintenance...........................................................................................................................................................371 Low Maintenance Battery Installation....................................................................................................................................................................371 Battery Installation, Low Maintenance...................................................................................................................................................................371 Low Maintenance Battery - OCV- Open Circuit Voltage Test................................................................................................................................................372 Battery Open Circuit Voltage (OCV), Low Maintenance.....................................................................................................................................................372 Low Maintenance Battery Load Test.......................................................................................................................................................................372 Battery Load Test, Low Maintenance.....................................................................................................................................................................372 Low Maintenance Battery Off-season Storage..............................................................................................................................................................373 Battery Off Season Storage, Low Maintenance............................................................................................................................................................373 Low Maintenance Battery Charging Procedure..............................................................................................................................................................373 Battery Charging Procedure, Low Maintenance............................................................................................................................................................373 CH 11 - INTERNATIONAL...........................................................................................................................................................................................375 800 EFI International BRAKE SYSTEM..........................................................................................................................................................................376 Brake System Overview, International........................................................................................................................................................................376 Overview................................................................................................................................................................................................376 Exploded View...........................................................................................................................................................................................377 Brake System Exploded View, International............................................................................................................................................................... 0 800 EFI International Steering Post and lock Assembly.......................................................................................................................................................378 Steering Lock, Exploded View............................................................................................................................................................................378 Steering Assembly Exploded View.........................................................................................................................................................................378 800 EFI INTERNATIONAL ELECTRICAL............................................................................................................................................................................379 Turn / Hazard Signal Diagram............................................................................................................................................................................379 INDEX...........................................................................................................................................................................................................381 WIRE DIAGRAMS...................................................................................................................................................................................................387
DESCRIPTION:
2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL
FOREWORD:
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL – PDF DOWNLOAD:
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1 review for 2007 POLARIS SPORTSMAN 700 800 800 X2 EFI 700 & 800 TWIN MODELS SERVICE REPAIR SHOP MANUAL – PDF DOWNLOAD
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Legacy Miguel –
To download the manuals is no problem but to open them or to find a app to open it is difficult