Polaris 2007 SPORTSMAN X2 800 Manuals

Manuals and User Guides for Polaris 2007 SPORTSMAN X2 800. We have 1 Polaris 2007 SPORTSMAN X2 800 manual available for free PDF download: Service Manual

Polaris 2007 SPORTSMAN X2 800 Service Manual

Polaris 2007 SPORTSMAN X2 800 Service Manual (393 pages)

2007 ATV

Brand: Polaris | Category: Offroad Vehicle | Size: 25.2 MB

Table of Contents

General Information Chapter 1 1

5
- Table of Contents
  5
- Chapter 1
  6
- Engine and Machine Serial Numbers
  6
  - General
    6
  - General Information
    7
- Engine Designation Numbers
  6
- Model Information
  6
- Model Number
  6
- Transmission I.D. Location
  6
- Vin Identification
  6
- Sportsman 'Deluxe' and 'Standard' Model Component Comparison
  8
- 2007 Sportsman 700 Efi
  10
- Fuel System
  11
- 2007 Sportsman 800 Efi
  12
- 2007 Sportsman X2 800 Efi
  14
- Misc. Numbers/Charts
  16
  - Standard Torque Specifications
    16
  - Special Tools
    16
  - Sae Tap Drill Sizes
    17
  - Metric Tap Drill Sizes
    17
  - Conversion Table
    18
  - Glossary of Terms
    19
Maintenance Chapter 2 Maintenance 2

21
- Chapter 2
  23
- Maintenance
  23
- Maintenance Chart Key
  23
- Overview
  23
- Periodic Maintenance Chart
  24
- Lubrication / Fluids
  27
- Vehicle Inspection
  34
  - Throttle Inspection
    35
  - Throttle Cable / Electronic Throttle Control Adjustment
    35
  - Fuel System
    36
  - Vent Lines
    36
  - Compression Test
    36
  - Engine Mounts
    37
  - Spark Plug
    37
  - Active Descent Control (Adc) Reservior Level
    37
  - Battery Maintenance
    38
  - Cooling System
    38
  - Coolant Strength / Type
    39
  - Cooling Hoses
    39
  - Radiator
    39
  - Cooling System Pressure Test
    39
  - Reservoir Level Inspection
    39
  - Radiator Coolant Level
    40
  - Air Filter Service
    40
  - Air Box Sediment Tube
    41
  - Engine Breather
    41
  - Pvt Inspection / Drying Procedure
    42
  - Engine Ground
    42
  - Engine Oil Level
    42
  - Oil/Filter Change
    43
  - Final Drive
    44
  - Steering Inspection
    44
  - Tie Rod / Steering
    44
  - Camber/Caster
    44
  - Wheel Alignment
    45
  - Toe Alignment
    45
  - Exhaust Pipe
    46
  - Brake System Inspection
    46
  - Brake Pads
    47
  - Brake Hose Inspection
    47
  - Auxiliary (Rear) Brake Test
    47
  - Auxiliary Brake Adjustment
    48
  - Suspension: Spring Preload Adjustment
    48
  - Front Suspension
    48
  - Rear Suspension
    48
  - CV Shaft Boot Inspection
    48
  - Atv Controls
    49
- Wheel Installation
  49
  - Wheel Inspection
    49
- Wheel Removal: Front or Rear
  49
- Frame, Nuts, Bolts, Fasteners
  50
- Front / Rear Storage Compartments
  50
- Tire Inspection
  50
- Tire Pressure
  50
- Cleaning and Storage of Atv
  53
Chapter 3 Engine

57
- Crankcase Exploded Views
  58
- Specifications
  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
    
    Electrical
    75
  - 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
    79
- (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
- Efi Exhaust System (Deluxe)
  115
  - Dual Exhaust Layout
    115
Fuel Injection Chapter 4 Fuel Injection

117
- Chapter 4
  118
- General Information
  118
- Special Tools
  118
- Service Notes
  119
- Efi System Exploded View
  120
- Efi System Component Locations
  121
- Fuel Lines - Quick Connect
  122
- Fuel Tank Assembly
  122
- Electronic Fuel Injection
  123
  - Principal Components
    123
  - Efi Operation Overview
    123
  - Initial Priming / Starting Procedure
    123
- Electronic Control Unit (Ecu)
  124
  - Operation Overview
    124
  - Ecu Service
    124
  - Ecu Replacement
    124
- Fuel Pump
  125
  - Operation Overview
    125
  - Fuel Pump Test
    125
  - Fuel Pump / Tank Assembly Replacement
    126
- Fuel Filters
  128
  - General Information
    128
  - Fuel Filter Service
    128
  - Fuel Filter Replacement
    128
- Fuel Pressure Regulator
  128
  - Operation Overview
    128
  - Fuel Pressure Regulator Test
    128
  - Fuel Pressure Regulator Replacement
    128
- Fuel Injectors
  129
  - Operation Overview
    129
  - Fuel Injector Service
    129
  - Fuel Injector Replacement
    129
- Crankshaft Position Sensor (Cps)
  130
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  131
- Throttle Position Sensor (Tps)
  131
- Engine Temperature Sensor
  134
  - Operation Overview
    134
  - Engine Temperature Sensor Test
    134
  - Engine Temperature Sensor Replacement
    134
- Diagnostics Using "Blink Codes
  135
  - Efi Troubleshooting
    136
- Troubleshooting
  135
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

141
- Chapter 5
  142
- Decal Replacement
  142
- General Information
  142
- Special Tools
  142
- Torque Specifications
  142
- Plastic Insert Removal / Installation
  143
- Body
  144
  - Side Panel Removal
    144
  - Front Cover Removal / Installation
    144
  - Foot Well Removal / Installation
    145
  - X2 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 Body Assembly Exploded View
    153
  - Body Rack Exploded Views
    154
  - Headlight Pod Exploded View
    155
- Steering
  156
  - Handlebar Block Installation Procedure
    156
  - Steering / A-Arm Exploded View
    157
  - A-Arm Replacement
    158
  - Ball Joint Replacement
    159
  - Steering Post Removal
    160
  - Steering Post Assembly
    160
- Suspension
  160
  - Front Strut Cartridge Replacement
    160
  - Strut Assembly
    161
  - Sportsman Rear Suspension Assembly
    162
  - X2 Rear Suspension Exploded View
    163
  - X2 Torsion Bar Exploded View
    164
- X2 Cargo Box
  165
  - Exploded View
    165
  - Removal / Installation
    166
- X2 Seat Assembly
  168
Clutch System Chapter 6 Clutch System

171
- Chapter 6
  172
- Component Fastener Torques
  172
- Special Tools
  172
- Special Tools and Specifications
  172
- Pvt Exploded Views
  173
- Pvt System
  176
  - Pvt Operation Overview
    176
  - Drive Clutch Operation
    176
  - Driven Clutch Operation
    176
  - Ebs Clutch Operation
    177
  - Pvt Maintenance / Inspection
    177
  - Drive Clutch Spring
    178
  - Optional Shift Weights
    179
  - Pvt Drying
    180
  - Pvt Disassembly
    180
  - Pvt Installation
    181
  - Drive Belt Removal / Inspection
    182
  - Drive Belt Installation
    183
  - Clutch Alignment
    184
  - Clutch Offset
    184
- Ebs Drive Clutch Service
  185
  - Drive Clutch Disassembly
    185
  - Spider Removal
    185
  - Button to Tower Clearance Inspection
    187
  - Shift Weight Inspection
    187
  - Drive Clutch Inspection
    187
  - Moveable Sheave Bushing Inspection
    188
  - Drive Clutch Bushing Service
    188
  - One-Way Clutch Inspection (Drive Clutch)
    190
  - Drive Clutch Reassembly
    190
- Ebs Driven Clutch Service
  192
- Standard Drive Clutch
  198
  - Drive Clutch Disassembly
    198
  - Spider Removal
    199
  - Button to Tower Clearance Inspection
    200
  - Shift Weight Inspection
    200
  - Drive Clutch Reassembly
    202
- Standard Driven Clutch
  204
  - Disassembly
    204
  - Inspection
    204
  - Assembly
    205
- Pvt Troubleshooting
  206
  - Overheating
    206
  - Problem, Cause and Remedy Chart
    207
Final Drive Chapter 7 Final Drive

209
- Chapter 7
  210
- Front Drive Axle
  210
  - Removal
    210
  - Installation
    212
- Gearcase Fluid / Capacity
  210
- Special Tools
  210
- Specifications
  210
- Torque Table
  210
- Front Drive Shaft (CV) Boot
  212
  - Inspection
    212
  - Replacement
    212
- Front Hub
  214
  - Disassembly
    214
  - Assembly
    214
- Prop Shaft - Front or Rear
  215
  - Removal and Installation
    215
- U-Joint
  215
  - Disassembly
    215
  - Assembly
    216
- Drive Axle Exploded Views
  218
  - Drive Shafts and Propshafts
    218
- Front Gearcase - Centralized Hilliard (Standard Models)
  219
  - Exploded View (Standard Models)
    219
  - Operation
    220
  - Gearcase Removal
    220
  - Disassembly / Inspection
    221
  - Reassembly / Inspection
    225
  - Setting Ring Gear Backlash
    226
  - Front Gearcase Diagnosis
    227
  - Gearcase Installation
    228
- Front Gearcase - Active Descent Control (Deluxe Models)
  229
  - Adc Gearcase Exploded View (Deluxe Models)
    229
  - Operation
    230
  - Adc Coil Testing
    231
  - Adc Differential Hydraulic Circuit Bleeding
    231
  - Disassembly / Inspection
    231
  - Adc Gearcase Piston Replacement Procedure
    235
  - Assembly
    237
- Rear Hub
  240
  - Removal
    240
  - Disassembly
    241
  - Assembly
    242
  - Installation
    242
- Rear Drive (CV) Shaft
  243
  - Removal
    243
  - Service
    244
  - CV Boot Replacement
    245
  - Installation
    246
  - Drive Shaft and CV Joint Handling Tips
    247
- Rear Gearcase
  247
  - Removal
    247
  - Disassembly and Inspection
    247
  - Reassembly
    249
  - Installation
    250
  - Rear Gearcase Exploded View
    251
Sportsman Transmission Chapter 8 Sportsman Transmission

255
- Sportsman Transmission
  256
- Transmission Exploded View
  256
- Chapter 8 Lubricant / Capacity
  258
- Specificiatons
  258
- Transmission Service
  258
  - Transmission Removal
    258
  - Disassembly
    259
  - Assembly
    264
  - Transmission Installation
    269
  - Troubleshooting
    270
Table of Contents

271
- Sportsman X2 Transmission
  272
- Transmission Exploded Views
  272
  - Mounting Exploded View
    274
- Specifications
  275
  - Torque Specifications
    275
  - Special Tools
    275
  - Lubrication
    275
- Transmission Service
  275
  - Gear Selector Removal
    275
  - Transmission Removal
    275
  - Transmission Installation
    277
  - Troubleshooting Checklist
    278
  - Transmission Disassembly
    279
  - Transmission Assembly
    284
  - Transmission Front Output Shaft Backlash Procedure
    285
Brakes Chapter 9 Brakes

291
- Chapter 9
  292
- Component Service Limits
  292
- Specifications
  292
- Torque Table
  292
- Brake System Exploded Views
  293
  - X2 System Component Exploded View
    293
  - Sportsman System Component Exploded View
    294
- Brake Caliper Exploded Views
  295
- Hydraulic Brake System
  296
  - Operation Overview
    296
  - Brake Noise Troubleshooting
    297
  - Brake Bleeding / Fluid Change
    297
- Front Master Cylinder
  299
  - Removal
    299
  - Installation
    299
- Front Brakes
  300
  - Pad Removal
    300
  - Assembly
    301
  - Brake Burnishing Procedure
    302
- Front Brake Disc
  302
  - Inspection
    302
  - Removal / Replacement
    303
- Front Caliper
  304
  - Removal
    304
  - Inspection
    305
  - Reassembly
    305
  - Installation
    306
- Rear Brake Pad
  307
  - X2 Pad Removal
    307
  - X2 Pad Installation
    308
  - Sportsman Rear Pad Removal
    309
  - Sportsman Rear Pad Installation
    310
  - Brake Burnishing Procedure
    310
- X2 Rear Caliper
  311
  - Removal
    311
  - Inspection
    312
  - Reassembly
    312
- Sportsman Rear Caliper
  313
  - Removal and Inspection
    313
  - Assembly
    314
- Rear Brake Disc
  315
  - Inspection
    315
- Rear Master Cylinder
  316
  - X2 Exploded View
    316
  - Overview
    317
  - X2 Rear Master Cylinder Removal and Installation
    317
  - Sportsman Rear Master Cylinder Removal / Installation
    318
  - Pedal Removal and Installation
    319
- Troubleshooting
  319
  - Brakes Squeal
    319
  - Poor Brake Performance
    319
  - Lever Vibration
    319
  - Caliper Overheats (Brakes Drag)
    319
  - Brakes Lock
    319
Chapter 10 Electrical

321
- Instrument Cluster
  323
- Overview
  323
- Instrument Cluster Diagnostic Mode
  324
- Setting a New Service Interval
  326
- Efi Diagnostic Mode
  327
- Speedometer Removal
  328
- Speedometer Installation
  329
- Speedometer Troubleshooting
  330
- Active Descent Control (Adc) Coil
  335
  - Operation Overview
    335
  - Diagnosing System Failures
    335
- All Wheel Drive (Awd) Coil
  335
- Cooling System Components
  336
  - Fan Control Circuit Operation / Testing
    336
  - Fan Control Circuit Bypass Test
    336
  - Coolant Temperature Sensor
    336
  - Fan Motor Current Draw
    337
- Gear Position Indicator Switch
  337
  - Test Diagram
    337
- Electronic Throttle Control (Etc) Switch
  338
  - Etc Switch Operation
    338
  - Etc Operation Test
    338
- Ignition System
  339
  - Flywheel Identification
    339
  - Efi - DC/CDI Ignition Overview
    339
  - Alternator/Ignition Components - 700/800 Efi
    340
  - Crankshaft Position Sensor Gap
    341
  - Ignition System Troubleshooting
    341
- Charging System
  341
  - Current Draw - Key off
    341
  - Charging System "Break Even" Test
    342
  - Alternator Output Test
    342
  - Charging System Testing Flow Chart
    344
- Relays
  345
  - Operation
    345
  - Power Relay
    345
- Fuses/Circuit Breaker
  346
  - Operation
    346
- Lighting
  346
- Fuel Sender
  353
  - Testing
    353
- X2 Differential System
  353
  - Solenoid Testing
    353
  - Solenoid Replacement
    353
  - Differential Relay Operation
    354
  - Differential Relay Testing
    354
- X2 Speed Sensor
  354
  - Testing
    354
  - Replacement
    354
- Accessory Power
  355
  - Wire Connections
    355
- International
  356
- Starter System
  356
  - 700/800 Starter Lockout Overview and Diagnostic
    356
  - 800 X2 Starter Lockout Overview and Diagnostic
    357
  - Troubleshooting
    358
  - Voltage Drop Test
    358
  - Starter Motor Removal / Disassembly
    358
  - Brush Inspection / Replacement
    359
  - Armature Testing
    360
  - Starter Reassembly / Installation
    361
  - Starter Solenoid Bench Test
    361
  - Starter Drive
    362
  - Starter Exploded View
    363
- Starter System Testing Flow Chart
  364
- Basic Winch Wiring- Pre-Wired Models
  365
- Battery
  366
- 800 Efi International Brake System
  376
- Chapter 11 Overview
  376
- 800 Efi International Steering Post and Lock Assembly
  378
  - Steering Assembly Exploded View
    378
- 800 Efi International Electrical
  379
  - Turn / Hazard Signal Diagram
    379

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