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2008 Polaris Sportsman X2 700 800 EFI 800 Touring Factory Service Repair Maintenance Manual – PDF DOWNLOAD
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2008 Polaris Sportsman X2 700 800 EFI 800 Touring Factory Service Repair Maintenance Manual
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Description
2008 Polaris Sportsman X2 700 800 EFI 800 Touring Factory Service Repair Maintenance Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:388
DOWNLOADABLE:YES
FILE TYPE:PDF
2008 POLARIS SPORTSMAN X2 700 800 EFI 800 TOURING FACTORY SERVICE REPAIR MAINTENANCE MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
2008 Polaris Sportsman X2 700 800 EFI 800 Touring Factory Service Repair Maintenance Manual
FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equrpped 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 positron. 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 e famrlrarwrth service procefgluCrTs before starting the work- Certain procedures require the use Of special tools. Use only the proper tools as specified .
TABLE OF CONTENTS:
2008 Polaris Sportsman X2 700 800 EFI 800 Touring Factory Service Repair Maintenance Manual
FOREWORD........................................................................................................................................................................................................ 1 FOREWORD.................................................................................................................................................................................................... 1 understanding manual safety labels and directions........................................................................................................................................................... 2 TRADEMARKS.................................................................................................................................................................................................. 2 CHAPTER INDEX................................................................................................................................................................................................... 3 CH 1 - GENERAL INFORMATION...................................................................................................................................................................................... 5 MODEL INFORMATION........................................................................................................................................................................................... 6 Model Number............................................................................................................................................................................................ 6 Engine Designation Numbers.............................................................................................................................................................................. 6 VIN Identification...................................................................................................................................................................................... 6 TRANSMISSION I.D. LOCATION.............................................................................................................................................................................. 6 Engine and Machine Serial Numbers....................................................................................................................................................................... 6 PUBLICATIONS............................................................................................................................................................................................ 7 PAINT CODES............................................................................................................................................................................................. 7 REPLACEMENT KEYS........................................................................................................................................................................................ 7 2008 SPORTSMAN 800 EFI...................................................................................................................................................................................... 8 MODEL NUMBER: A08MN76AF, AL, AQ, AS, AX................................................................................................................................................................. 8 2008 SPORTSMAN X2 700 EFI................................................................................................................................................................................... 10 MODEL NUMBER: A08TN68AZ, AX............................................................................................................................................................................. 10 2008 SPORTSMAN TOURING 800 EFI.............................................................................................................................................................................. 12 MODEL NUMBER: A08DN76AF, AG, AH, AL, AL, AS / A08DN76FC, FH............................................................................................................................................. 12 MISC. NUMBERS/CHARTS........................................................................................................................................................................................ 14 Standard Torque Specifications.......................................................................................................................................................................... 14 SPECIAL TOOLS........................................................................................................................................................................................... 14 SAE Tap Drill Sizes..................................................................................................................................................................................... 15 Metric Tap Drill Sizes.................................................................................................................................................................................. 15 Decimal Equivalents..................................................................................................................................................................................... 15 Conversion Table........................................................................................................................................................................................ 16 Glossary Of Terms....................................................................................................................................................................................... 17 CH 2 - MAINTENANCE.............................................................................................................................................................................................. 19 MAINTENANCE................................................................................................................................................................................................. 21 Overview................................................................................................................................................................................................ 21 Periodic Maintenance Chart.............................................................................................................................................................................. 22 LUBRICATION / FLUIDS........................................................................................................................................................................................ 25 SPORTSMAN Component Locations........................................................................................................................................................................... 25 SPORTSMAN X2-Touring Component Locations................................................................................................................................................................ 26 Polaris Lubricants, Maintenance and Service Products.................................................................................................................................................... 27 Polaris Lubricant Symbol Identification................................................................................................................................................................. 28 Pre-Ride / Daily Inspection............................................................................................................................................................................. 28 Lubrication / Grease Points............................................................................................................................................................................. 29 Front Gearcase Lubrication.............................................................................................................................................................................. 30 Rear Gearcase Lubrication - 800 EFI..................................................................................................................................................................... 31 Transmission Lubrication ............................................................................................................................................................................... 32 ADC Differential Hydraulic Circuit Fluid Change......................................................................................................................................................... 33 VEHICLE INSPECTION.......................................................................................................................................................................................... 33 Shift Link Rod Inspection............................................................................................................................................................................... 33 Throttle Inspection..................................................................................................................................................................................... 34 Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment.................................................................................................................................... 34 Fuel System............................................................................................................................................................................................. 35 Vent Lines.............................................................................................................................................................................................. 35 Compression Test........................................................................................................................................................................................ 35 Engine Mounts........................................................................................................................................................................................... 36 Spark Plug ............................................................................................................................................................................................. 36 Active Descent Control (ADC) Reservoir Level............................................................................................................................................................ 36 Battery Maintenance..................................................................................................................................................................................... 37 Cooling System.......................................................................................................................................................................................... 37 Coolant Strength / Type................................................................................................................................................................................. 38 Cooling Hoses........................................................................................................................................................................................... 38 Radiator................................................................................................................................................................................................ 38 Cooling System Pressure Test............................................................................................................................................................................ 38 Reservoir Level Inspection.............................................................................................................................................................................. 38 Radiator Coolant Level.................................................................................................................................................................................. 39 Air Filter Service...................................................................................................................................................................................... 39 Air Box Sediment Tube................................................................................................................................................................................... 40 Engine Breather Hose.................................................................................................................................................................................... 40 PVT Inspection / Drying Procedure....................................................................................................................................................................... 41 Engine Ground........................................................................................................................................................................................... 41 Engine Oil Level........................................................................................................................................................................................ 41 Oil/filter Change....................................................................................................................................................................................... 42 Steering Inspection..................................................................................................................................................................................... 43 Tie Rod / Steering...................................................................................................................................................................................... 43 Camber/Caster........................................................................................................................................................................................... 43 Wheel Alignment......................................................................................................................................................................................... 44 Toe Alignment........................................................................................................................................................................................... 44 Exhaust Pipe............................................................................................................................................................................................ 45 Brake System Inspection................................................................................................................................................................................. 45 Brake Pads.............................................................................................................................................................................................. 46 Brake Hose Inspection................................................................................................................................................................................... 46 Auxiliary (Rear) Brake Test............................................................................................................................................................................. 46 Auxiliary Brake Adjustment.............................................................................................................................................................................. 47 Suspension: Spring Preload Adjustment................................................................................................................................................................... 47 Front Suspension........................................................................................................................................................................................ 47 Rear Suspension......................................................................................................................................................................................... 47 CV Shaft Boot Inspection................................................................................................................................................................................ 47 ATV Controls............................................................................................................................................................................................ 48 Wheel Inspection........................................................................................................................................................................................ 48 Wheel Removal: Front Or Rear............................................................................................................................................................................ 48 Wheel Installation...................................................................................................................................................................................... 48 Tire Pressure........................................................................................................................................................................................... 49 Tire Inspection......................................................................................................................................................................................... 49 Frame, Nuts, Bolts, Fasteners........................................................................................................................................................................... 49 Front / Rear Storage Compartments....................................................................................................................................................................... 49 Winch Operation (If Equipped)........................................................................................................................................................................... 50 Cleaning And Storage Of ATV............................................................................................................................................................................. 52 Maintenance Schedule.................................................................................................................................................................................... 55 Maintenance Schedule.................................................................................................................................................................................... 56 CH 3 - ENGINE................................................................................................................................................................................................... 57 SPECIFICATIONS.............................................................................................................................................................................................. 58 Crankcase Exploded Views................................................................................................................................................................................ 58 Engine Fastener Torque Patterns......................................................................................................................................................................... 65 Torque Specifications................................................................................................................................................................................... 66 700/800 EFI Engine Service Specifications............................................................................................................................................................... 67 Special Tools........................................................................................................................................................................................... 69 GENERAL ENGINE SERVICE...................................................................................................................................................................................... 70 Accessible Components................................................................................................................................................................................... 70 Piston Identification................................................................................................................................................................................... 70 Cooling System Specifications........................................................................................................................................................................... 70 Cooling System Pressure Test............................................................................................................................................................................ 71 Four Stroke - Coolant Air Bleeding Procedure............................................................................................................................................................ 71 Engine Removal (Typical)................................................................................................................................................................................ 72 Engine Installation Notes............................................................................................................................................................................... 74 Cylinder Hone Selection And Honing Procedure............................................................................................................................................................ 74 Honing To Deglaze....................................................................................................................................................................................... 75 Cleaning the Cylinder After Honing...................................................................................................................................................................... 75 Oil Flow Chart.......................................................................................................................................................................................... 76 Engine Lubrication Specifications....................................................................................................................................................................... 76 OIL PRESSURE TEST....................................................................................................................................................................................... 76 ENGINE DISASSEMBLY AND INSPECTION........................................................................................................................................................................... 77 Cylinder Head Assembly Exploded View.................................................................................................................................................................... 77 Rocker Arms............................................................................................................................................................................................. 78 Push Rods............................................................................................................................................................................................... 78 Cylinder Head Removal .................................................................................................................................................................................. 78 Cylinder Head Inspection................................................................................................................................................................................ 79 Cylinder Head Warp...................................................................................................................................................................................... 79 Valve Seal/Spring Service (On Engine)................................................................................................................................................................... 79 Cylinder Head Disassembly............................................................................................................................................................................... 80 Valve Inspection........................................................................................................................................................................................ 81 Combustion Chamber...................................................................................................................................................................................... 82 Valve Seat Reconditioning............................................................................................................................................................................... 82 Cylinder Head Reassembly................................................................................................................................................................................ 84 Valve Sealing Test...................................................................................................................................................................................... 85 Cylinder Removal........................................................................................................................................................................................ 85 Valve Lifter Removal/Inspection......................................................................................................................................................................... 85 Piston Removal.......................................................................................................................................................................................... 86 Cylinder Inspection..................................................................................................................................................................................... 87 Piston-To-Cylinder Clearance............................................................................................................................................................................ 88 Piston/rod Inspection................................................................................................................................................................................... 88 Piston Ring Installed Gap............................................................................................................................................................................... 89 Starter Drive/Bendix Removal Inspection ................................................................................................................................................................ 89 Flywheel / Stator Removal / Inspection.................................................................................................................................................................. 90 Engine Crankcase Disassembly / Inspection............................................................................................................................................................... 91 Camshaft Inspection..................................................................................................................................................................................... 98 ENGINE REASSEMBLY........................................................................................................................................................................................... 99 CRANKCASE REASSEMBLY.................................................................................................................................................................................... 99 Flywheel / Stator Installation..........................................................................................................................................................................110 Cylinder Head Reassembly................................................................................................................................................................................111 TROUBLESHOOTING.............................................................................................................................................................................................113 Engine..................................................................................................................................................................................................113 Cooling System..........................................................................................................................................................................................114 800 EFI Exhaust System......................................................................................................................................................................................115 Dual Exhaust Layout.....................................................................................................................................................................................115 CH 4 - FUEL INJECTION...........................................................................................................................................................................................117 GENERAL INFORMATION.........................................................................................................................................................................................118 Special Tools...........................................................................................................................................................................................118 Service Notes...........................................................................................................................................................................................120 EFI System Exploded View................................................................................................................................................................................121 EFI System Component Locations..........................................................................................................................................................................122 Fuel Tank Assembly......................................................................................................................................................................................123 Fuel Lines - Quick Connect..............................................................................................................................................................................123 ELECTRONIC FUEL INJECTION...................................................................................................................................................................................124 Principal Components....................................................................................................................................................................................124 EFI Operation Overview..................................................................................................................................................................................124 Initial Priming / Starting Procedure....................................................................................................................................................................124 ELECTRONIC CONTROL UNIT (ECU)...............................................................................................................................................................................125 Operation Overview......................................................................................................................................................................................125 ECU Service.............................................................................................................................................................................................125 ECU Replacement.........................................................................................................................................................................................125 FUEL PUMP...................................................................................................................................................................................................126 Operation Overview......................................................................................................................................................................................126 Fuel Pump Test..........................................................................................................................................................................................126 Fuel Pump / Tank Assembly Replacement...................................................................................................................................................................127 FUEL PRESSURE REGULATOR.....................................................................................................................................................................................128 Operation Overview......................................................................................................................................................................................128 Fuel Pressure Regulator Test............................................................................................................................................................................128 Fuel Pressure Regulator Replacement.....................................................................................................................................................................128 FUEL FILTER.................................................................................................................................................................................................128 General Information.....................................................................................................................................................................................128 Fuel Filter Service.....................................................................................................................................................................................128 Fuel Filter Replacement.................................................................................................................................................................................128 FUEL INJECTORS..............................................................................................................................................................................................129 Operation Overview......................................................................................................................................................................................129 Fuel Injector Service...................................................................................................................................................................................129 Fuel Injector Replacement...............................................................................................................................................................................129 CRANKSHAFT POSITION SENSOR (CPS)............................................................................................................................................................................130 Operation Overview......................................................................................................................................................................................130 Crankshaft Position Sensor Test.........................................................................................................................................................................130 Crankshaft Position Sensor (CPS) Replacement............................................................................................................................................................130 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)........................................................................................................................................................131 Operation Overview......................................................................................................................................................................................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 Replacement....................................................................................................................................................................131 Throttle Position Sensor Test...........................................................................................................................................................................132 Throttle Position Sensor Initialization.................................................................................................................................................................132 ENGINE TEMPERATURE SENSOR...................................................................................................................................................................................134 Operation Overview......................................................................................................................................................................................134 Engine Temperature Sensor Test..........................................................................................................................................................................134 Engine Temperature Sensor Replacement...................................................................................................................................................................134 TROUBLESHOOTING.............................................................................................................................................................................................135 Diagnostics Using “Blink Codes”.........................................................................................................................................................................135 EFI Troubleshooting.....................................................................................................................................................................................136 EFI CIRCUIT - Power On..................................................................................................................................................................................137 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 Special Tools ..........................................................................................................................................................................................142 Decal Replacement.......................................................................................................................................................................................142 Plastic Insert Removal / Installation...................................................................................................................................................................143 BODY........................................................................................................................................................................................................144 Side Panel Removal......................................................................................................................................................................................144 Front Cover Removal / Installation......................................................................................................................................................................144 Foot Well Removal / Installation........................................................................................................................................................................145 X2-Touring Foot Well Removal / Installation.............................................................................................................................................................145 Front Storage Removal...................................................................................................................................................................................146 Front Storage Installation..............................................................................................................................................................................148 Sportsman Rear Rack Removal / Installation..............................................................................................................................................................148 Front Cab/Fender Removal/Installation...................................................................................................................................................................149 Sportsman Rear Cab / Fender Removal / Installation......................................................................................................................................................150 X2 Rear Quarter Panel Removal / Installation............................................................................................................................................................150 Sportsman Rear Storage Removal / Installation...........................................................................................................................................................151 Radiator Screen Removal.................................................................................................................................................................................151 Sportsman Body Assembly Exploded View...................................................................................................................................................................152 X2- Touring Body Assembly Exploded View.................................................................................................................................................................153 Touring Body/Rack Assembly Exploded View................................................................................................................................................................154 Body / Rack Exploded Views..............................................................................................................................................................................155 Touring Body/Seat Assembly Exploded View................................................................................................................................................................156 Headlight Pod Exploded View.............................................................................................................................................................................157 STEERING....................................................................................................................................................................................................158 Handlebar Block Installation Procedure..................................................................................................................................................................158 Steering / A-arm Exploded View..........................................................................................................................................................................159 A-Arm Replacement.......................................................................................................................................................................................160 Ball Joint Replacement..................................................................................................................................................................................161 Steering Post Removal...................................................................................................................................................................................162 Steering Post Assembly..................................................................................................................................................................................162 SUSPENSION..................................................................................................................................................................................................162 Front Strut Cartridge Replacement.......................................................................................................................................................................162 Strut Assembly..........................................................................................................................................................................................163 Sportsman Rear Suspension Assembly......................................................................................................................................................................164 X2- Touring Rear Suspension Exploded View...............................................................................................................................................................165 X2 Torsion Bar Exploded View............................................................................................................................................................................166 X2 CARGO BOX................................................................................................................................................................................................167 Exploded View...........................................................................................................................................................................................167 Removal / Installation..................................................................................................................................................................................168 X2 SEAT assembly............................................................................................................................................................................................170 Exploded Views..........................................................................................................................................................................................170 X2 Seat Operation - Configuring Cargo Box For Passenger Riding..........................................................................................................................................171 X2 Driver Seat Backrest Removal / Installation..........................................................................................................................................................172 X2 Passenger Seat Backrest Removal / Installation.......................................................................................................................................................172 CH 6 - CLUTCH SYSTEM............................................................................................................................................................................................175 SPECIAL TOOLS AND SPECIFICATIONS............................................................................................................................................................................176 Special Tools...........................................................................................................................................................................................176 Component Fastener Torques..............................................................................................................................................................................176 PVT EXPLODED VIEWS..........................................................................................................................................................................................177 PVT Sealing And Ducting Components......................................................................................................................................................................177 Drive Clutch Exploded Views (EBS vs. Non-EBS)...........................................................................................................................................................177 Driven Clutch Exploded Views............................................................................................................................................................................178 Engine Braking System (EBS) Exploded View...............................................................................................................................................................179 PVT SYSTEM..................................................................................................................................................................................................180 PVT Operation Overview..................................................................................................................................................................................180 Drive Clutch Operation..................................................................................................................................................................................180 Driven Clutch Operation.................................................................................................................................................................................180 EBS Clutch Operation....................................................................................................................................................................................181 PVT Maintenance / Inspection............................................................................................................................................................................181 Drive Clutch Spring.....................................................................................................................................................................................182 Optional Shift Weights..................................................................................................................................................................................183 PVT Drying..............................................................................................................................................................................................184 PVT Disassembly ........................................................................................................................................................................................184 PVT Installation........................................................................................................................................................................................185 Drive Belt Removal / Inspection.........................................................................................................................................................................186 DRIVE BELT INSTALLATION.................................................................................................................................................................................187 Clutch Alignment........................................................................................................................................................................................188 Clutch Offset...........................................................................................................................................................................................188 EBS DRIVE CLUTCH SERVICE....................................................................................................................................................................................189 Drive Clutch Disassembly................................................................................................................................................................................189 Spider Removal..........................................................................................................................................................................................189 Button To Tower Clearance Inspection....................................................................................................................................................................191 Shift Weight Inspection.................................................................................................................................................................................191 Drive Clutch Inspection.................................................................................................................................................................................191 Moveable Sheave Bushing Inspection......................................................................................................................................................................192 Drive Clutch Bushing Service............................................................................................................................................................................192 One-Way Clutch Inspection (Drive Clutch)................................................................................................................................................................194 Drive Clutch Reassembly.................................................................................................................................................................................194 EBS DRIVEN CLUTCH SERVICE...................................................................................................................................................................................196 Driven Clutch Disassembly ..............................................................................................................................................................................196 DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION.............................................................................................................................................................198 EBS DRIVEN CLUTCH REASSEMBLY............................................................................................................................................................................199 PVT TROUBLESHOOTING.........................................................................................................................................................................................203 Overheating.............................................................................................................................................................................................203 Problem, Cause and Remedy Chart.........................................................................................................................................................................204 CH 7 - FINAL DRIVE..............................................................................................................................................................................................207 SPECIFICATIONS..............................................................................................................................................................................................208 Torque Table............................................................................................................................................................................................208 Special Tools...........................................................................................................................................................................................208 Gearcase Fluid / Capacity...............................................................................................................................................................................208 FRONT HUB...................................................................................................................................................................................................208 Disassembly.............................................................................................................................................................................................208 Assembly................................................................................................................................................................................................209 FRONT DRIVE SHAFT (CV) SERVICE..............................................................................................................................................................................209 Removal.................................................................................................................................................................................................209 Installation............................................................................................................................................................................................210 Inspection..............................................................................................................................................................................................211 CV Joint/Boot Replacement...............................................................................................................................................................................211 PROP SHAFT - FRONT OR REAR..................................................................................................................................................................................213 Removal and Installation................................................................................................................................................................................213 U-JOINT.....................................................................................................................................................................................................213 Disassembly.............................................................................................................................................................................................213 Assembly................................................................................................................................................................................................214 DRIVE AXLE EXPLODED VIEWS...................................................................................................................................................................................216 Drive Shafts and Propshafts.............................................................................................................................................................................216 FRONT GEARCASE - CENTRALIZED HILLIARD W/ Active descent control.............................................................................................................................................217 Operation...............................................................................................................................................................................................217 ADC Gearcase Exploded View..............................................................................................................................................................................218 ADC Operation...........................................................................................................................................................................................219 Front Gearcase Diagnosis................................................................................................................................................................................220 Gearcase Removal........................................................................................................................................................................................221 Gearcase Installation...................................................................................................................................................................................222 Coil Testing............................................................................................................................................................................................223 ADC Differential Hydraulic Circuit Bleeding.............................................................................................................................................................223 Disassembly / Inspection................................................................................................................................................................................223 ADC Gearcase Piston Replacement Procedure...............................................................................................................................................................227 Assembly................................................................................................................................................................................................229 Setting Ring Gear Backlash..............................................................................................................................................................................232 REAR HUB....................................................................................................................................................................................................233 Removal.................................................................................................................................................................................................233 Disassembly.............................................................................................................................................................................................234 Assembly................................................................................................................................................................................................235 Installation............................................................................................................................................................................................235 REAR DRIVE (CV) SHAFT.......................................................................................................................................................................................236 Removal.................................................................................................................................................................................................236 Service.................................................................................................................................................................................................237 CV Boot Replacement.....................................................................................................................................................................................238 INSTALLATION............................................................................................................................................................................................239 Drive Shaft and CV Joint Handling Tips..................................................................................................................................................................239 REAR GEARCASE...............................................................................................................................................................................................240 Removal.................................................................................................................................................................................................240 Disassembly and Inspection..............................................................................................................................................................................240 Reassembly..............................................................................................................................................................................................241 Installation ...........................................................................................................................................................................................242 Rear Gearcase Exploded View.............................................................................................................................................................................244 sPORTSMAN 8.3-8.18..........................................................................................................................................................................................245 sPORTSMAN X2 8.19-8.38......................................................................................................................................................................................245 CH 8 - TRANSMISSION / SPORTSMAN.................................................................................................................................................................................247 TRANSMISSION EXPLODED VIEW..................................................................................................................................................................................248 Sportsman Transmission .................................................................................................................................................................................248 SPECIFICIATONS..............................................................................................................................................................................................250 Torque Specifications...................................................................................................................................................................................250 Lubricant / Capacity....................................................................................................................................................................................250 TRANSMISSION SERVICE........................................................................................................................................................................................250 Transmission Removal....................................................................................................................................................................................250 Disassembly.............................................................................................................................................................................................251 Assembly................................................................................................................................................................................................256 Transmission Installation...............................................................................................................................................................................261 Troubleshooting.........................................................................................................................................................................................262 CH 8 - TRANSMISSION / X2 AND TOURING............................................................................................................................................................................263 TRANSMISSION EXPLODED VIEWS.................................................................................................................................................................................264 Transmission Exploded View..............................................................................................................................................................................264 Mounting Exploded View..................................................................................................................................................................................266 SPECIFICATIONS..............................................................................................................................................................................................267 Torque Specifications...................................................................................................................................................................................267 Special Tools...........................................................................................................................................................................................267 Lubrication.............................................................................................................................................................................................267 TRANSMISSION SERVICE........................................................................................................................................................................................267 Gear Selector Removal...................................................................................................................................................................................267 Transmission Removal....................................................................................................................................................................................267 Transmission Installation...............................................................................................................................................................................269 Troubleshooting Checklist...............................................................................................................................................................................270 Transmission Disassembly................................................................................................................................................................................271 Transmission assembly...................................................................................................................................................................................277 Transmission front output shaft backlash procedure......................................................................................................................................................278 CH 9 - BRAKES...................................................................................................................................................................................................283 SPECIFICATIONS..............................................................................................................................................................................................284 Torque Table............................................................................................................................................................................................284 Component Service Limits................................................................................................................................................................................284 BRAKE SYSTEM Exploded Views.................................................................................................................................................................................285 X2, Touring System Component Exploded View..............................................................................................................................................................285 Sportsman System Component Exploded View................................................................................................................................................................286 BRAKE CALIPER EXPLODED VIEWS................................................................................................................................................................................287 Sportsman and X2, Touring Front Caliper Assembly........................................................................................................................................................287 X2, Touring Rear Caliper Assembly.......................................................................................................................................................................287 Sportsman Rear Caliper Assembly.........................................................................................................................................................................288 HYDRAULIC BRAKE SYSTEM......................................................................................................................................................................................288 Operation Overview......................................................................................................................................................................................288 Brake Noise Troubleshooting.............................................................................................................................................................................289 Brake Bleeding / Fluid Change...........................................................................................................................................................................289 FRONT MASTER CYLINDER.......................................................................................................................................................................................291 Removal.................................................................................................................................................................................................291 Installation............................................................................................................................................................................................291 FRONT BRAKES................................................................................................................................................................................................292 Pad Removal.............................................................................................................................................................................................292 Assembly................................................................................................................................................................................................293 Brake Burnishing Procedure..............................................................................................................................................................................294 FRONT BRAKE DISC............................................................................................................................................................................................294 Inspection..............................................................................................................................................................................................294 Removal / Replacement...................................................................................................................................................................................295 FRONT CALIPER...............................................................................................................................................................................................296 Removal.................................................................................................................................................................................................296 Inspection..............................................................................................................................................................................................297 Reassembly..............................................................................................................................................................................................297 Installation............................................................................................................................................................................................298 REAR BRAKE PAD..............................................................................................................................................................................................299 X2, Touring Pad Removal.................................................................................................................................................................................299 X2, Touring Pad Installation............................................................................................................................................................................300 Sportsman Rear Pad Removal..............................................................................................................................................................................301 Sportsman Rear Pad Installation.........................................................................................................................................................................302 Brake Burnishing Procedure..............................................................................................................................................................................302 X2, TOURING REAR CALIPER....................................................................................................................................................................................303 Removal.................................................................................................................................................................................................303 Inspection..............................................................................................................................................................................................304 Reassembly..............................................................................................................................................................................................304 Sportsman REAR CALIPER......................................................................................................................................................................................305 Removal and Inspection..................................................................................................................................................................................305 Assembly................................................................................................................................................................................................306 REAR BRAKE DISC.............................................................................................................................................................................................307 Inspection..............................................................................................................................................................................................307 REAR MASTER CYLINDER........................................................................................................................................................................................308 X2, Touring Exploded View...............................................................................................................................................................................308 Overview................................................................................................................................................................................................309 X2, Touring Rear Master Cylinder Removal and Installation...............................................................................................................................................309 Sportsman Rear Master Cylinder Removal / Installation...................................................................................................................................................310 Pedal Removal and Installation..........................................................................................................................................................................311 TROUBLESHOOTING.............................................................................................................................................................................................311 Brakes Squeal...........................................................................................................................................................................................311 Poor Brake Performance..................................................................................................................................................................................311 Lever Vibration.........................................................................................................................................................................................311 Caliper Overheats (Brakes Drag).........................................................................................................................................................................311 Brakes Lock.............................................................................................................................................................................................311 CH 10 - ELECTRICAL..............................................................................................................................................................................................313 INSTRUMENT CLUSTER .........................................................................................................................................................................................315 Overview................................................................................................................................................................................................315 Instrument Cluster Diagnostic Mode......................................................................................................................................................................316 Setting A New Service Interval..........................................................................................................................................................................318 EFI Diagnostic Mode.....................................................................................................................................................................................319 Speedometer Removal.....................................................................................................................................................................................320 Speedometer Installation................................................................................................................................................................................321 SPEEDOMETER TROUBLESHOOTING.................................................................................................................................................................................322 Test 1 - No All Wheel Drive.............................................................................................................................................................................322 TEST 2 - No Display / TEST 3 - No Reverse Speed Limit...................................................................................................................................................323 TEST 4 - No AWD Hub Safety Limiter......................................................................................................................................................................324 TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor .................................................................................................................................................325 TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch...................................................................................................................................................326 ACTIVE DESCENT CONTROL (ADC) COIL...........................................................................................................................................................................327 Operation Overview......................................................................................................................................................................................327 Diagnosing System Failures..............................................................................................................................................................................327 ALL WHEEL DRIVE (AWD) COIL..................................................................................................................................................................................327 Operation Overview......................................................................................................................................................................................327 Diagnosing System Failures..............................................................................................................................................................................327 COOLING SYSTEM COMPONENTS...................................................................................................................................................................................328 Fan Control Circuit Operation / Testing.................................................................................................................................................................328 Fan Control Circuit Bypass Test.........................................................................................................................................................................328 Coolant Temperature Sensor..............................................................................................................................................................................328 Fan Motor Current Draw..................................................................................................................................................................................329 GEAR POSITION INDICATOR SWITCH..............................................................................................................................................................................329 Test Diagram............................................................................................................................................................................................329 ELECTRONIC THROTTLE CONTROL (ETC) SWITCH....................................................................................................................................................................330 ETC Switch Operation....................................................................................................................................................................................330 ETC Operation Test......................................................................................................................................................................................330 IGNITION SYSTEM.............................................................................................................................................................................................331 Flywheel Identification.................................................................................................................................................................................331 EFI - DC/CDI Ignition Overview..........................................................................................................................................................................331 Alternator/Ignition Components - 700/800 EFI............................................................................................................................................................332 Crankshaft Position Sensor Gap..........................................................................................................................................................................333 Ignition System Troubleshooting.........................................................................................................................................................................333 CHARGING SYSTEM.............................................................................................................................................................................................333 Current Draw - Key Off..................................................................................................................................................................................333 Charging System “Break Even” Test.......................................................................................................................................................................334 Alternator Output Test..................................................................................................................................................................................334 Charging System Testing Flow Chart......................................................................................................................................................................336 RELAYS......................................................................................................................................................................................................337 Operation...............................................................................................................................................................................................337 FUSES/Circuit Breaker.......................................................................................................................................................................................338 Operation...............................................................................................................................................................................................338 LIGHTING....................................................................................................................................................................................................338 High Beam Headlight Bulb Replacement....................................................................................................................................................................338 Headlight Housing Replacement...........................................................................................................................................................................339 High Beam Headlight Adjustment .........................................................................................................................................................................340 Lower Headlamp Removal / Installation...................................................................................................................................................................340 Low Beam Headlight Adjustment...........................................................................................................................................................................341 Headlamp Switch Test....................................................................................................................................................................................341 Work Light / Differential Switch........................................................................................................................................................................342 Sportsman / Touring Brake Light / Work Light Replacement................................................................................................................................................342 X2 BRAKE LIGHT / WORK LIGHT REPLACEMENT.................................................................................................................................................................343 Brake Light Switch......................................................................................................................................................................................344 FUEL SENDER.................................................................................................................................................................................................345 Testing.................................................................................................................................................................................................345 X2 / Touring DIFFERENTIAL System............................................................................................................................................................................345 Solenoid Testing........................................................................................................................................................................................345 Solenoid Replacement....................................................................................................................................................................................345 Differential Relay Operation............................................................................................................................................................................346 Differential Relay Testing..............................................................................................................................................................................346 X2 / TOURING SPEED SENSOR...................................................................................................................................................................................346 Testing.................................................................................................................................................................................................346 Replacement.............................................................................................................................................................................................346 ACCESSORY POWER.............................................................................................................................................................................................347 Wire Connections........................................................................................................................................................................................347 STARTER SYSTEM..............................................................................................................................................................................................348 Sportsman Starter Lockout Overview and Diagnostic.......................................................................................................................................................348 X2 /TOURING Starter Lockout Overview and Diagnostic.....................................................................................................................................................349 Troubleshooting.........................................................................................................................................................................................350 Voltage Drop Test.......................................................................................................................................................................................350 Starter Motor Removal / Disassembly ....................................................................................................................................................................350 BRUSH INSPECTION / REPLACEMENT..........................................................................................................................................................................351 Armature Testing........................................................................................................................................................................................352 Starter Reassembly / Installation.......................................................................................................................................................................353 Starter Solenoid Bench Test.............................................................................................................................................................................353 Starter Drive...........................................................................................................................................................................................354 Starter Exploded View...................................................................................................................................................................................355 STARTER SYSTEM TESTING FLOW CHART...........................................................................................................................................................................356 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....356 BASIC WINCH WIRING- PRE-WIRED MODELS........................................................................................................................................................................357 BATTERY.....................................................................................................................................................................................................358 Battery Identification..................................................................................................................................................................................358 Battery Activation (Conventional).......................................................................................................................................................................358 Battery Terminals/Bolts.................................................................................................................................................................................359 Conventional Battery Inspection / Removal...............................................................................................................................................................359 Conventional Battery Installation.......................................................................................................................................................................359 Conventional Battery Testing............................................................................................................................................................................360 Conventional Battery OCV - Open Circuit Voltage Test....................................................................................................................................................360 Conventional Battery Specific Gravity Test..............................................................................................................................................................360 Battery Load Test.......................................................................................................................................................................................361 Off Season Storage......................................................................................................................................................................................361 Charging Procedure......................................................................................................................................................................................361 Low Maintenance Battery.................................................................................................................................................................................362 Low Maintenance Battery Charging........................................................................................................................................................................362 Low Maintenance Battery Inspection / Removal............................................................................................................................................................363 Low Maintenance Battery Installation....................................................................................................................................................................363 Low Maintenance Battery - OCV- Open Circuit Voltage Test................................................................................................................................................364 Low Maintenance Battery Load Test.......................................................................................................................................................................364 Low Maintenance Battery Off-season Storage..............................................................................................................................................................365 Low Maintenance Battery Charging Procedure..............................................................................................................................................................365 TROUBLESHOOTING DIAGRAMS....................................................................................................................................................................................366 Overview................................................................................................................................................................................................366 All Wheel Drive - EFI...................................................................................................................................................................................366 Charging Circuit - EFI..................................................................................................................................................................................366 Cooling Fan - EFI.......................................................................................................................................................................................367 Fuel Pump - EFI.........................................................................................................................................................................................367 Gear Switch - EFI.......................................................................................................................................................................................368 Power Circuit - EFI.....................................................................................................................................................................................368 Reverse Override - EFI..................................................................................................................................................................................369 Fan Control - EFI.......................................................................................................................................................................................369 Start Circuit - EFI.....................................................................................................................................................................................370 Start Enable - EFI......................................................................................................................................................................................370 CH 11 - INTERNATIONAL TOURING...................................................................................................................................................................................371 800 TOURING EFI International BRAKE SYSTEM..................................................................................................................................................................372 Overview................................................................................................................................................................................................372 Exploded View...........................................................................................................................................................................................373 800 TOURING EFI International Steering Post and lock Assembly...............................................................................................................................................374 Steering Assembly Exploded View.........................................................................................................................................................................374 800 TOURING EFI INTERNATIONAL ELECTRICAL....................................................................................................................................................................375 Turn / Hazard Signal Diagram............................................................................................................................................................................375 INDEX...........................................................................................................................................................................................................377 WIRE DIAGRAMS...................................................................................................................................................................................................383
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
