improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting

or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris 2007 SPORTSMAN X2 800

Page 1 2007 Sportsman 700/800/ 800 X2 EFI Service Manual PN 9920378 © Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 3 GENERAL MAINTENENCE ENGINE FUEL SYSTEM BODY / SUSPENSION CLUTCH TRANSMISSION FINAL DRIVE BRAKES ELECTRICAL INTERNATIONAL...
Page 4 NOTES...
Page 5: Table Of Contents
2007 SPORTSMAN X2 800 EFI ........
Page 6: Model Information
GENERAL INFORMATION MODEL INFORMATION Engine and Machine Serial Numbers Be sure to refer to the engine model number and serial number Model Number whenever corresponding about an engine. The machine model number must be used with any correspondence regarding warranty or service. This information can be found on the sticker applied to the top side of the crankcase (A).
Page 7: General Information
Sportsman 800 EFI 2007 A07MH76F 9920374 9920379 International PAINT CODES Table 1-2: Paint Codes COLOR DITZLER POLARIS PAINTED PART DESCRIPTION NUMBER NUMBER Sportsman 700/800 EFI Frame Black 9440 P-067 REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
Page 8: Sportsman 'Deluxe' And 'Standard' Model Component Comparison
GENERAL INFORMATION Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL Winch No Winch PXT Tires Titan Tires PVT w/EBS Non-EBS (800 X2 excluded)
Page 9 GENERAL INFORMATION Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL Winch No Winch Rear Work Lights No Work Lights Front Drive w/ Active Descent Control (ADC)
Page 10: 2007 Sportsman 700 Efi
GENERAL INFORMATION 2007 SPORTSMAN 700 EFI MODEL NUMBER: A07MH68AX, AY, AZ (Standard Model Only) ENGINE MODEL: EH068OLE Table 1-4: Sportsman 700 EFI General Specifications Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm Wheel Base...
Page 11: Fuel System
Lubrication Pressurized Wet Sump Front Travel 8.2 in. / 21 cm Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Rear Suspension / Shock Progressive Rate Independent - Exhaust System Single Pipe USFS Approved Coil - over shock...
Page 12: 2007 Sportsman 800 Efi
GENERAL INFORMATION 2007 SPORTSMAN 800 EFI MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA (Standard) (Deluxe) (International) ENGINE MODEL: EH076OLE Table 1-8: Sportsman 800 EFI General Specifications Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height...
Page 13 Lubrication Pressurized Wet Sump Front Suspension / Shock A-arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 liters Front Travel 8.2 in. / 21 cm Exhaust System Dual Pipe / Silencer (Deluxe) Single Pipe / Silencer (Standard)
Page 14: 2007 Sportsman X2 800 Efi
GENERAL INFORMATION 2007 SPORTSMAN X2 800 EFI MODEL NUMBER: A07TH76AU, A07TN76AF (Standard) (Deluxe) ENGINE MODEL: EH076OLE Table 1-12: Sportsman X2 800 EFI General Specifications Category Dimension / Capacity Length 93 in./236.22 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm...
Page 15 Lubrication Pressurized Wet Sump Front Travel 8.2 in. / 21 cm Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 liters Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Exhaust System Single Pipe / Silencer Rear Travel 8.75 in.
Page 16: Misc. Numbers/Charts
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
Page 17: Sae Tap Drill Sizes
GENERAL INFORMATION SAE Tap Drill Sizes Decimal Equivalents 1/64 ....0156 Thread Size/ Drill Size Thread Size / Drill Size 1/32 ....0312 .
Page 18: Conversion Table
GENERAL INFORMATION Conversion Table Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.
Page 19: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 20 GENERAL INFORMATION NOTES 1.16...
Page 21 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... . 2.8 POLARIS LUBRICANT SYMBOL IDENTIFICATION ......2.9 PRE-RIDE / DAILY INSPECTION .
Page 22 MAINTENANCE WHEEL REMOVAL: FRONT OR REAR ........2.28 WHEEL INSTALLATION .
Page 23: Maintenance
Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING: Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.
Page 24: Periodic Maintenance Chart
Inspect periodically Battery 20 H Monthly 125 (200) Check terminals; clean; test = Perform these procedures more often for vehicles subjected to severe use. E = Emission Control System Service (California) = Have an authorized Polaris Dealer perform these services.
Page 25 Inspect routing, condition (iff applicable) Valve Clearance 100 H 12 M 620 (1000) Inspect; = Perform these procedures more often for vehicles subjected to severe use. E = Emission Control System Service (California) = Have an authorized Polaris Dealer perform these services.
Page 26 ---- Inspect daily, adjust as needed Headlight aim ---- Adjust as needed = Perform these procedures more often for vehicles subjected to severe use. E = Emission Control System Service (California) = Have an authorized Polaris Dealer perform these services.
Page 27: Lubrication / Fluids
MAINTENANCE LUBRICATION / FLUIDS SPORTSMAN Component Locations (Deluxe) (Sportsman Only)
Page 28 MAINTENANCE SPORTSMAN X2 Component Locations Instrument Cluster AWD/Turf Switch Brake Fluid Reservoir Worklight (Speedometer) Brake Lever Diagnostic Light Control Port (under access panel) & Run Switch Throttle Reverse Override Ignition/Key Front Storage Compartment & Rack Front Demand Drive Unit Rear Dump Box / Passenger Area (Behind Radiator) Battery (Under Tank) Oil Dipstick...
Page 29: Polaris Lubricants, Maintenance And Service Products
MAINTENANCE Polaris Lubricants, Maintenance and Service Table 2-2: Products PART DESCRIPTION NUMBER Table 2-2: Coolant PART DESCRIPTION 2871323 60/40 Coolant (Gallon) (6 count) NUMBER 2871534 60/40 Coolant (Quart) (12 count) Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc.
Page 30: Polaris Lubricant Symbol Identification
MAINTENANCE Polaris Lubricant Symbol Identification Pre-Ride / Daily Inspection NOTE: The symbols used are for quick reference in identifying Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. which lubricant/grease to use on each component.
Page 31: Lubrication / Grease Points
Annually or 100 hours of operation (refer to Maintenance Schedule for additional information). More often under severe conditions (operating in water or hauling heavy loads. Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special 2.11...
Page 32: Front Gearcase Lubrication
• Be sure vehicle is level before proceeding and in PARK • Check vent hose to be sure it is routed properly and unobstructed • The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. FRONT GEARCASE...
Page 33: Transmission Lubrication
Remove transmission drain plug to drain the oil. Discard used oil properly. Clean and reinstall the drain plug. Torque to specification. Remove fill plug. Add the correct amount of Polaris AGL Gearcase Lubricant. Check for leaks. Oil Fill Plug Install fill plug. Torque to specification.
Page 34: Adc Differential Hydraulic Circuit Fluid Change
Shift Mount inadequate bleed of the hydraulic circuit. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Polaris ADC hydraulic fluid. (AW ISO 10 hydraulic fluid equivalent). Locate bleeder valves found on either side of differential Shifter and remove the protective caps.
Page 35: Throttle Inspection
MAINTENANCE Throttle Inspection Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever Slide boot off throttle cable adjuster and jam nut. must return freely without binding.
Page 36: Fuel System
MAINTENANCE Fuel System Remove fuel lines from filter, use shop towels to catch any leaking fuel. Install new filter in line with arrow pointed in direction of WARNING fuel flow. Install line locks on fuel lines and verify locks are seated. Gasoline is extremely flammable and explosive Start engine and inspect for leaks.
Page 37: Engine Mounts
The Active Descent Control reservoir (DELUXE Models Only) is located by the radiator fill cap. Check the level and verify it is between the ‘MAX’ and ‘MIN’ lines. Add only Polaris ADC fluid when required. Clean with electrical contact cleaner or a glass bead spark plug cleaner only.
Page 38: Battery Maintenance
Observe coolant levels often during the break-in period. • Overheating of engine could occur if air is not fully purged from system. • Polaris Premium 60/40 anti-freeze is premixed and ready to use. Do not dilute with water. 2.18...
Page 39: Coolant Strength / Type
Remove reservoir cap. Verify the inner splash cap vent Cooling Hoses hole is clear and open. Fill reservoir to upper mark with Polaris Premium 60/40 Inspect all hoses for cracks, deterioration, abrasion or leaks. Anti Freeze / Coolant (PN 2871323) or a mixture of Replace if necessary.
Page 40: Radiator Coolant Level
MAINTENANCE Radiator Coolant Level Remove clips (A) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around. WARNING Never remove the radiator pressure cap when the engine is warm or hot. Escaping steam and fluid can cause severe burns.
Page 41: Air Box Sediment Tube
MAINTENANCE NOTE: Apply a small amount of general purpose NOTE: The sediment tube will require more frequent grease to the sealing edges of the filter before service if the vehicle is operated in wet conditions or reinstalling. at high throttle openings for extended periods. Engine Breather Proper Filter Main Filter...
Page 42: Pvt Inspection / Drying Procedure
MAINTENANCE PVT Inspection / Drying Procedure Engine Oil Level NOTE: If operating the ATV in or through water, be The twin engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level: sure to check the PVT cover and other components for water ingestion.
Page 43: Oil/Filter Change
11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil. 13. Place gear selector in park and set the parking brake. 2.23...
Page 44: Final Drive
Due to the critical nature of the procedures outlined first, and then at front and rear. Try to move the wheel in this chapter, Polaris recommends steering and hub by pushing inward and pulling outward. component repair and adjustment be performed by •...
Page 45: Wheel Alignment
MAINTENANCE Wheel Alignment Toe Alignment Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod Set handlebars in a straight ahead position and secure needs adjusting.
Page 46: Exhaust Pipe
(See Chapter 9) wheels. Make sure the machine is in neutral and repeat • Use Polaris DOT-approved Brake Fluid. Steps 2 and 3. See WARNING in this section. • Check brake system for fluid leaks, look for dust build...
Page 47: Brake Pads
MAINTENANCE Brake Hose Inspection • Inspect thickness of brake pad friction material (see Chapter 9) Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any Sight Glass worn or damaged parts. Parking Lock Brake Auxiliary (Rear) Brake Test The auxiliary brake (A) should be checked for proper function.
Page 48: Auxiliary Brake Adjustment
If the rubber boot Free Play exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have your Polaris dealer 1 inch or greater replace the boot.
Page 49: Atv Controls
MAINTENANCE ATV Controls Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Check controls for proper operation, positioning and adjustment. Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.
Page 50: Tire Pressure
MAINTENANCE Tire Pressure Front / Rear Storage Compartments The front and rear storage (Sportsman Only) compartments are CAUTION easily accessible. To open the front compartment turn the latch handle to the horizontal position on both sides. To close the storage compartment turn the latch handles to the vertical position.
Page 51 MAINTENANCE Winch Operation (If Equipped) The mini-rocker (IN/OUT) control controls the direction of the cable for the winch. IN pulls the cable into the winch and OUT feeds the cable out of the winch. This information is for Sportsman models equipped with a winch in the front.
Page 52 MAINTENANCE Winch Wire Locations Locate the Red wire (6 Ga.) with the yellow crimp cover is located in the rear fender area. The red wire connects to the battery. The winch wires can be located under the front cab area. Locate the wires, remove the cap and hook up to winch the Blue and Yellow (6 Ga.) wires to the winch.
Page 53: Cleaning And Storage Of Atv
Polaris dealer for free replacement. Warm the engine and change the oil and filter. Follow the Polaris does not recommend the use of a high pressure type car procedure in this chapter for proper oil change. wash system for washing the ATV. If a high pressure system is...
Page 54 Always place the transmission in park and lock the parking brake. Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section of the Be sure the fuel cap, oil cap and seat are installed correctly.
Page 55 MAINTENANCE 800 EFI Dual Exhaust Canister Maintenance (Sportsman Only) The canisters on select dual exhaust Polaris Sportsman 800 EFIs are silver ceramic coated. To maintain a (X2 not applicable) beautiful finish and prevent corrosion, periodic maintenance is required. CAUTION DO NOT use caustic chemicals to clean, as they may damage the finish.
Page 56 MAINTENANCE Maintenance Schedule Service Date Hours / Miles Service Performed Serviced By: 2.36...
Page 57 ENGINE CHAPTER 3 ENGINE SPECIFICATIONS ............3.2 CRANKCASE EXPLODED VIEWS .
Page 58: Specifications
ENGINE SPECIFICATIONS Crankcase Exploded Views A. JournalBearings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N. Crankcase O.
Page 59 (6.8 ± .68 Nm) Apply corrosion resistant grease to stator grommet area. 96 ± 3 in.lbs. (10.85 ± 0.35 Nm) Oil Pump Bolt Tighten Sequence Mag Cover Bolt Tighten Sequence Apply Polaris OW-40 oil to component Apply White Lithium Grease...
Page 60 Starter / Flywheel / Water Pump Exploded View Apply Polaris Water Pump Cover Starter Grease Bolt Tighten Sequence Apply Polaris 0W-40 oil to seal Loctite™ Pipe Sealant (PN 2871956) No Grease or Oil 84 ± 8 ft.lbs. (9.5 ± 0.9 Nm) 96 ±...
Page 61 ENGINE Oil System / Level Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring 50 ± 5 in.lbs. (5.64 E. Hex Plug ± 0.56 Nm) F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug 22 ±...
Page 62 A. Head Bolts B. Rocker Arms C. Head Assembly D. Gasket E. Pushrods Circlip UP F. Bushing for Install G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Hydraulic Lifter Apply Polaris 0W--40 Oil Apply Moly Lube Grease...
Page 63 ENGINE Engine Sensors & Misc. Exploded View 84 ± 4 in.lbs. (9.5 ± 0.9 Nm) A. Screws 20 ± 5 in.lbs. B. Rocker Cover (2.5 ± 0.55 Nm) C. Breather D. O-ring Seal E. Breather Bolts 18 ± 2 ft.lbs. F.
Page 64 ENGINE EFI Harness Exploded View A. Fuel Injector B. Fuel Rail C. EFI Harness 18 ± 2 ft.lbs. (24.5 ± 2.7 Nm) NOTE: See Chapter 4 for more information on the EFI system.
Page 65: Engine Fastener Torque Patterns
ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 22 ± 2 ft.lbs. (30 ± 3 Nm) Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then °...
Page 66: Torque Specifications
ENGINE Torque Specifications Table 3-1: Engine Torque Specifications . (N . (N ASTENER Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Carburetor Adaptor Bolts 8 mm 216 ±...
Page 67: 700/800 Efi Engine Service Specifications
ENGINE 700/800 EFI Engine Service Specifications Table 3-1: Engine Specifications EH068OLE / EH076OLE OMPONENT YLINDER Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) 1.654" ± 0.00039" (42 ± 0.010 mm) Camshaft Journal Outer Diameter - Mag 1.634"± 0.00039" (41.50 ± 0.010 mm) Camshaft Journal Outer Diameter - Center 1.614"...
Page 68 ENGINE Table 3-2: Engine Specifications OMPONENTS YLINDER ISTON EH068OLE EH076OLE ONNECTING Cylinder - Surface warp limit 0.004" (0.10 mm) 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031"...
Page 69: Special Tools
ENGINE Table 3-3: Engine Specifications EH068OLE EH076OLE OMPONENTS ISTON ONNECTING 0.0059 ± 0.138" 0.0059± 0.138" Top Ring - Standard (0.15 ± 0.35mm) (0.15 ± 0.35mm) Top Ring - Limit > 15% Leakdown > 15% Leakdown 0.0098 ± 0.197" 0.0098 ± 0.197" Second Ring - Standard Installed (0.25 ±...
Page 70: General Engine Service
• Counterbalance Shaft or Bearings restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ • Connecting Rod Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 71: Cooling System Pressure Test
10 psi. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, Polaris Premium clamps and water pump seals for leakage. Antifreeze...
Page 72: Engine Removal (Typical)
ENGINE Engine Removal (Typical) Relieve the fuel pressure in the fuel rail (refer to Chapter 4, FUEL INJECTION") for proper procedure. Carefully remove the fuel rail (B) and injectors. WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual.
Page 73 ENGINE 14. Refer to PVT System Chapter 6 to remove outer clutch 19. Remove all engine mount nuts and / or engine mount plates. cover, drive belt, drive clutch, driven clutch, and inner Remove the frame brace (G) from the front left side of the cover (F).
Page 74: Engine Installation Notes
Engine Installation Notes Engine Break-In Period The break-in period for a Polaris ATV engine is defined as the After the engine is installed in the frame, review this checklist first ten hours of operation, or the time it takes to use two full and perform all steps that apply: tanks of gasoline.
Page 75: Electrical
Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant. 3.19...
Page 76: Oil Flow Chart
NOTE: Use only Polaris Premium 0W-40 Synthetic Filter Wrench - PV-43527 or equivalent Engine Lubricant. - Oil Pressure Specification - 35-39 PSI @ 5500 RPM, Polaris 0W-40 Synthetic , Oil Pressure at 5500 RPM (Engine Hot): Engine at operating temperature. Standard: 39 PSI Minimum: 35 PSI 3.20...
Page 77: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) :Push Rods Spring Retainers Springs Valve Seals Cylinder Head Hydraulic Lifters Valves 3.21...
Page 78: Rocker Arms
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal Inspect the wear pad at the valve end of the rocker arm for Loosen the six cylinder head bolts evenly 1/8 turn each in indications of scuffing or abnormal wear.
Page 79: Cylinder Head Inspection
ENGINE Cylinder Head Inspection Valve Seal/Spring Service (On Engine) Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.
Page 80: Cylinder Head Disassembly
ENGINE Cylinder Head Disassembly Remove valve guide seals. IMPORTANT: It is recommended to replace seals Carefully remove the cylinder components. Place the whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause hydraulic lifters (C), pushrods (D), and rocker arms (E) in excessive oil consumption and carbon buildup.
Page 81: Valve Inspection
ENGINE Valve Inspection measurements total). Compare to specifications. Remove all carbon from valves with a soft wire wheel or Measure valve stem in several places. brush. Rotate the valve 90 degrees and measure Check valve face for runout, pitting, and burnt spots. To for wear.
Page 82: Combustion Chamber
Valve Seat Reconditioning Install pilot into valve guide. NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced.
Page 83 ENGINE Inspect the cut area of the seat: NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is * If the contact area is less than 75% of the circumference of the a normal condition.
Page 84: Cylinder Head Reassembly
ENGINE Lubricate the valve guides with clean engine oil, and apply Valve seals should be installed after the valves are in the oil or water based lapping compound to the face of the head to avoid valve seal damage. Install new valve seals valve.
Page 85: Valve Sealing Test
ENGINE Valve Lifter Removal/Inspection Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end Remove the valve lifter's by reaching into the crankcase of the valves to seat the split keepers. and pushing the lifter up through the lifter bore by hand.
Page 86: Piston Removal
ENGINE Piston Removal *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly. Repeat procedure for second ring.
Page 87: Cylinder Inspection
ENGINE Cylinder Inspection Inspect cylinder for wear, scratches, or damage. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
Page 88: Piston-To-Cylinder Clearance
ENGINE Piston-To-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.
Page 89: Piston Ring Installed Gap
ENGINE Measure piston ring to groove clearance by placing the ring thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance to remove residue and prevent rust.
Page 90: Flywheel / Stator Removal / Inspection
ENGINE Inspect gear teeth on starter drive (B). Replace starter drive Install Flywheel Puller (PN 2871043) and remove if gear teeth are cracked, worn, or broken. flywheel (A). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be Inspect the bendix bushing (C) in the mag cover for wear.
Page 91: Engine Crankcase Disassembly / Inspection
ENGINE Engine Crankcase Disassembly / Inspection Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do not thread the puller bolts into the Remove the stator cover (A) and water pump cover (B). flywheel more than 1/4, or stator coils may be damaged. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft.
Page 92 ENGINE Note the positions of the gears in the photo. 10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.
Page 93 ENGINE 13. With a white marking pen, accent the timing mark on the 16. Insert the pointed dowels from the Tapered Pins (PU- gear that contains the springs. 45497-1) into the cam gear. PU-45497-1 Accent Timing Marks To Assemble: 14. Inspect the gear teeth and the three tabs on the gears for wear.
Page 94 ENGINE NOTE: Install the Cam Gear Alignment Tool (PU- 18. Line up the two gears using the timing marks and the three 45497-2) into one assembly hole counter clockwise gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely. from the timing mark.
Page 95 ENGINE 22. Remove the bolt and nut from the balance shaft gear. Try 25. Install the Flywheel Puller (PN 2871043) and remove the to remove the balance shaft gear. If the gear does not come crankshaft gear, if needed. off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.
Page 96 ENGINE NOTE: Be sure to place the tapered end of the valve 28. Use a feeler gauge to measure the clearance between the (dowel) in first. If the valve is installed incorrectly, two rotors. Measure the gap between the two rotor tips as shown below.
Page 97 ENGINE 33. Place the shaft in a press to remove the bearing. 36. Press gear onto shaft while supporting the housing. Bearing 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). New Bearing 35. Press the bearing/shaft assembly using the bearing's outer race.
Page 98: Camshaft Inspection
ENGINE NOTE: Only remove the oil baffle if the baffle is 41. Remove and inspect crankshaft main journal bearings for damaged. When removing the oil baffle bolts, use a abnormal wear. It is recommended to replace the ™ heat gun to heat the bolts and loosen the Loctite bearings anytime the engine is disassembled.
Page 99: Engine Reassembly
ENGINE ENGINE REASSEMBLY Measure camshaft journal outside diameters (O.D.). CRANKCASE REASSEMBLY CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU-45778) and a 3/4-full oil filter before initial start-up. Follow Steps 45-46 of this section to prime the engine and to help aid proper break-in.
Page 100 ENGINE NOTE: Always install new balance shaft bearings. Apply Crankcase Sealant (PN 2871557) to the top gearcase halve. NOTE: Do not apply sealant to cam relief hole (E). Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install cam and Assemble the crankcase halves.
Page 101 ENGINE Lubricate lifters with engine oil and install in the original 12. Orientate the piston rings on the piston before installation order as removed in disassembly. Apply Lubriplate or into the cylinders. Set the gaps of the rings evenly 120° Moly Lube to the ends of the lifters.
Page 102 ENGINE 14. Position cylinder and piston assemblies onto the connecting 16. Install camshaft thrust plate (G) with new bolts. Torque rods and push the piston pins through the piston and bolts to specification. connecting rods. Push In Piston Pins NOTE: New bolts have patch lock on the threads 15.
Page 103 ENGINE NOTE: The application of lubrication aids in priming NOTE: Occasionally spin pump when the oil pump during initial engine start up. installing bolts to check for binding of the rotors. Lubricate Rotors 19. Align the bolt holes and install oil pump assembly into crankcase.
Page 104 ENGINE 22. Before installing the crankshaft gear (I), heat the crankshaft 25. Install counter balance shaft gear (J) with new key, aligning ° ° gear to 250 F (121 C) on a hot plate (J). timing marks with crankshaft gear (I). Install washer and bolt.
Page 105 ENGINE NOTE: Cam Spanner Wrench (PU-45498) is only Before installing the gear/stator housing, replace the seals in the needed to rotate the camshaft when the entire valve train is assembled. Timing Marks PU-45498 Counterbalance Gear and Camshaft Gear Bolt Torque: 22 ±...
Page 106 ENGINE 28. Install a new crankshaft seal (P) into the gear/stator housing 30. Carefully install the tapered end of the Crankshaft Seal cover (O). Use the Universal Driver Handle (PU-45543) Protection Tool (PA-45658) through the paper side of the and the Main Seal Installer (PA-45483) to seat the crankshaft seal.
Page 107 ENGINE 33. Apply Crankcase Sealant (PN 2871557) to the outside 35. Secure the gear/stator housing cover (O) to the crankcase edges of the crankcase halves (See arrows), where the with the cover bolts. Torque bolts in proper sequence to crankcases mate. (See photos below.) This helps to prevent specification.
Page 108 ENGINE 37. Install water pump impeller (P). Secure the impeller with 39. Sparingly apply Starter Drive Grease (PN 2871423) to the the washer and a new nylok nut (Q). Torque the nut to starter drive. Install the starter bendix. specification. NOTE: There are thrust washers on both sides of starter drive.
Page 109 45. Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until resistance is felt. Remove the adapter. Apply sealant to the plug threads.
Page 110: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation Inspect the mating surface around the gear/stator housing cover and the crankcase for oil seepage. If there is seepage NOTE: Before assembly, clean the bolts and bolt between the mating surfaces, then the gear/stator housing holes with Primer N (PN 2870585) to remove any cover must be resealed.
Page 111: Cylinder Head Reassembly
ENGINE Cylinder Head Reassembly Lubricate push rods (D) and install into lifters. NOTE: Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. Install the head gasket (A) on the cylinder (B). Lubricate rockers (E) with engine oil.
Page 112 ENGINE Install breather reed (G) into rocker cover (H). Lightly 11. Install thermostat (J), new O-ring, and thermostat housing. apply black RTV sealant to the outer edges of the breather Torque to specification. reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification.
Page 113: Troubleshooting
ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark Engine • Broken throttle cable Spark Plug Fouling • Obstruction in air intake • Spark plug cap loose or faulty • Air box removed (reinstall all intake components) •...
Page 114: Cooling System
ENGINE Cooling System Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance Overheating • Wet sumping due to over-full crankcase • Low coolant level • Worn rings, piston, or cylinder • Air in cooling system • Worn valve guides or seals •...
Page 115: Efi Exhaust System (Deluxe)
Dual Exhaust Layout ™ After removing the stains, polish using Liquid Buff The dual exhaust canisters on select Polaris 800 EFIs are silver a soft cloth. ceramic coated. To maintain a beautiful finish and prevent corrosion, periodic maintenance is required. DO NOT use Repeat this procedure as often as desired to maintain the caustic chemicals to clean, as they may damage the finish.
Page 116 ENGINE NOTES 3.60...
Page 117 FUEL INJECTION CHAPTER 4 FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
Page 118: General Information
* Always stop the engine and refuel outdoors or in a Polaris EFI Diagnostic Software (Digital Wrench™) - PU- 47063 well ventilated area. This dealer-only software installs on laptop computers equipped...
Page 119: Service Notes
• 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris ATV EFI of the same model may be used without damaging system or engine components.
Page 120: Efi System Exploded View
FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature/Barometric Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump/Tank Assy. 7 Fuel Rail 8. Engine Coolant Sensor (ECT) 9.
Page 121: Efi System Component Locations
FUEL INJECTION EFI System Component Locations 11. Engine Coolant Temperature Sensor (ECT) Electronic Control Unit (ECU) Intake Air Temperature and Barometric Air Pressure Sensor (T-BAP) Crankshaft Position Sensor (CPS) Fuel Injectors 2 Fuel Filters (1 located in tank, 1 under front cab cover not pictured) Fuel Pump / Regulator / Gauge Sender Assembly (located In tank as an assembly...
Page 122: Fuel Tank Assembly
FUEL INJECTION Fuel Tank Assembly Fuel Lines - Quick Connect Sportsman 700/800 EFI models use quick connect fuel lines. Refer to the steps below for fuel line removal. Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back.
Page 123: Electronic Fuel Injection
• Wire Harness Assembly NOTE: Accurate testing of EFI components is • Check Engine Light (MIL) recommended utilizing Polaris Diagnostic EFI Operation Overview Software (dealer only). The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions.
Page 124: Electronic Control Unit (Ecu)
For the purpose of troubleshooting, a known-good ECU from Instrument cluster. The ECU requires a minimum of 7.0 volts to another Polaris ATV EFI of the same model may be used operate. The memory in the ECU is operational the moment the without system or engine component damage.
Page 125: Fuel Pump
Fuel Pump Remove the fuel test valve cap. Connect the pressure hose of the Polaris pressure tester (PN PU-43506) to the test valve on the fuel rail. Route the clear hose into a portable Internal 30 Micron gasoline container or the equipment fuel tank.
Page 126: Fuel Pump / Tank Assembly Replacement
FUEL INJECTION If the pump did not activate (Step 2), disconnect the plug Remove the clamps on the PVT intake duct and remove the from the fuel pump. Connect a DC voltmeter across PVT duct. terminals “A” and “C” in the plug, turn on the key switch and observe if a minimum of 7 volts is present.
Page 127 FUEL INJECTION Relieve the fuel pressure at the fuel test valve (arrow). Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank. 7. Loosen the fuel tank hose and pull the fuel line from Carefully pull the fuel tank out of the frame.
Page 128: Fuel Pressure Regulator
FUEL INJECTION FUEL PRESSURE REGULATOR FUEL FILTERS Operation Overview General Information The fuel pressure regulator maintains the required operating NOTE: All EFI units utilize quick connect fuel lines. system pressure of 39 psi + 3psi. A rubber-fiber diaphragm divides the regulator into two separate sections-, the fuel EFI Engines use a non-serviceable, high-volume, high- chamber and the pressure regulating chamber.
Page 129: Fuel Injectors
FUEL INJECTION FUEL INJECTORS NOTE: Do not apply voltage directly to the fuel injector(s). Excessive voltage will burn out the injector(s). Do not ground the injector(s) with the Operation Overview ignition on." lnjector(s) will open/turn on if relay is energized. NOTE: All EFI units utilize quick connect fuel lines.
Page 130: Crankshaft Position Sensor (Cps)
FUEL INJECTION CRANKSHAFT POSITION SENSOR Disconnect speed sensor connector from wiring harness. (the connector with one heavy black lead) Viewing the (CPS) connector with dual aligning rails on top, test resistance between the terminals. A reading of 560Ω ± 10% should Operation Overview again be obtained.
Page 131: Temperature / Barometric Air Pressure Sensor (T-Bap)
If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate, therefore the T-BAP sensor should only be tested using the Polaris Diagnostic Software (dealer only). Refer to the EFI Diagnostic Software Manual for more information.
Page 132: Throttle Position Sensor Test
FUEL INJECTION Throttle Position Sensor Test low, verify the 9 volt battery is good or try a new 9 volt battery. The throttle position sensor (TPS) is a non-serviceable item. If it is faulty, it must be replaced. It can be tested using the following method: •...
Page 133 FUEL INJECTION • With engine off, back out air flow screw until it no STEP 2 longer is in contact with throttle plate cam. The throttle plate should seal off throttle bore completely. Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow Back Air Flow Screw Out Until No value.
Page 134: Engine Temperature Sensor
‘HOT’ should indicate on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 10 for ETS testing. Polaris dealers can also test the sensor by using the Polaris Digital Wrench‘ Software (dealer only). Refer to the Digital Wrench‘ Software Manual for more information.
Page 135: Troubleshooting
FUEL INJECTION TROUBLESHOOTING NOTE: To clear codes manually, disconnect the positive battery lead for 20 seconds. Diagnostics Using “Blink Codes” To enable the blink codes, turn the ignition from “OFF” to “ON” 3 times, leaving it 'on' the 3rd time, within 5 seconds. Any “blink codes”...
Page 136: Efi Troubleshooting
FUEL INJECTION EFI Troubleshooting Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when Fuel Starvation / Lean Mixture engine is warm) Symptoms: Hard start or no start, bog, backfire, popping • Throttle stop screw set incorrect through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle •...
Page 137 FUEL INJECTION EFI CIRCUIT - Power On EFI CIRCUIT - Crank Position Sensor 4.21...
Page 138 FUEL INJECTION EFI CIRCUIT - Fuel Pump EFI CIRCUIT - Throttle Position Sensor 4.22...
Page 139 FUEL INJECTION EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor EFI CIRCUIT - Engine Temperature 4.23...
Page 140 FUEL INJECTION EFI CIRCUIT - Malfunction Indicator Light 4.24...
Page 141 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION GENERAL INFORMATION ..........5.2 TORQUE SPECIFICATIONS .
Page 142: General Information
BODY / STEERING / SUSPENSION GENERAL INFORMATION Special Tools Table 5-2: Torque Specifications Table 5-1: UMBER ESCRIPTION 2870871 Ball Joint Replacement Tool OMPONENT 2870872 Shock Spanner Wrench Front Hug Nut Shock Absorber Spring Compression 2870623 Tool Front A-Arm Attaching Bolt 2871572 Strut Rod Wrench Front A-Arm Ball Joint Stud Nut...
Page 143: Plastic Insert Removal / Installation
To install the inserts, press outside insert (B) into the hole. Press inside insert (A) until it snaps into place. Some Polaris ATVs use a two piece plastic insert in place of a NOTE: The outside insert (B) should be flush metal screw.
Page 144: Body
BODY / STEERING / SUSPENSION BODY Reinstall the side panel by reversing the removal procedure. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Remove seat by releasing the latch and lifting up on the seat.
Page 145: Foot Well Removal / Installation
BODY / STEERING / SUSPENSION Foot Well Removal / Installation X2 Foot Well Removal / Installation Remove the four plastic inserts (A) that secure the wheel Remove the four plastic inserts (A) that secure the wheel well to the front and rear cabs. (See “PLASTIC INSERT well to the front and rear cabs.
Page 146: Front Storage Removal
BODY / STEERING / SUSPENSION Front Storage Removal Remove the four bolts that secure the storage rack to the frame. Front Storage Remove Bolts Remove the two (T25) screws that secure the storage box to the front fender well areas (each side). Remove Bolts T-25 Screws Remove the front radiator cap cover (A) by lifting upward...
Page 147 BODY / STEERING / SUSPENSION Winch Installation Area Remove the front headlights (C) or simply disconnect the electric connector (D) before removing the front plastic Remove the front cover piece by lifting up on sides of the bumper. two locking tabs as shown. Pull the tabs out of the notches and lift up on the cover piece.
Page 148: Front Storage Installation
BODY / STEERING / SUSPENSION Front Storage Installation Install the front radiator cap cover (E) . Front Storage Sportsman Rear Rack Removal / Installation inserts T-25 Screw A. 14 ft.lbs. (19 Nm) C. 10 in.lbs. (1.13 Nm) B. 10 in.lbs. (1.13 Nm) D.
Page 149: Front Cab/Fender Removal/Installation
BODY / STEERING / SUSPENSION Place spacers on frame. Remove the two screws (B) that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. Remove the side panels (D), refer to the “SIDE PANEL Install the two bolts (B) and six (A) T-27 screws.
Page 150: Sportsman Rear Cab / Fender Removal / Installation
BODY / STEERING / SUSPENSION Sportsman Rear Cab / Fender Removal / Disconnect the rear lights by pulling the locks on each side Installation and removing the connectors. Lift the rear cab from the frame. Follow the “REAR RACK REMOVAL” procedure to remove the rear rack.
Page 151: Sportsman Rear Storage Removal / Installation
BODY / STEERING / SUSPENSION Sportsman Rear Storage Removal / Radiator Screen Removal Installation Pull out slightly on the top of the radiator screen. Follow the “REAR RACK REMOVAL” and “REAR With the top free, pull out on the bottom of the screen to CAB REMOVAL”...
Page 152: Sportsman Body Assembly Exploded View
BODY / STEERING / SUSPENSION Sportsman Body Assembly Exploded View Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat. Seat Latch Rear Cab Wheelwell Storage Frame Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard...
Page 153: X2 Body Assembly Exploded View
BODY / STEERING / SUSPENSION X2 Body Assembly Exploded View Rear Cab Assembly Footwell RH Rear Cab Frame Footwell Support Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard Support Front Cab Splash Shields 5.13...
Page 154: Body Rack Exploded Views
BODY / STEERING / SUSPENSION Body / Rack Exploded Views Rack Rails Sportsman Only Rear Rack Rear Rack Support Rack Rails Frame Box Assembly Cover Front Brush Guard Panel Radiator Shield Grill Radiator Screen Front Bumper 5.14...
Page 155: Headlight Pod Exploded View
BODY / STEERING / SUSPENSION Headlight Pod Exploded View Worklight Switch Instrument Cluster Brake Clean knurling when repositioning handlebars Wheel Speed Sensor - Sportsman (X2 Speed Sensor Located on Transmission) Disassembly Assembly • Remove two side Phillips screws (A) • Install bottom of pod onto handlebar and secure to brackets •...
Page 156: Steering
BODY / STEERING / SUSPENSION STEERING Handlebar Block Installation Procedure Clean knurling when repositioning handlebars The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation.
Page 157: Steering / A-Arm Exploded View
BODY / STEERING / SUSPENSION Steering / A-arm Exploded View 30 ft.lbs. (41 Nm) Steering Post 25-30 ft.lbs. (35-41 Nm) 30 ft.lbs. (41 Nm) Steering Post Arm 8 ft.lbs. (11 Nm) 25 ft.lbs. (35 Nm) 12-14 ft.lbs. (17-19 Nm) 40-45 ft.lbs. (54-61 Nm) Always use new cotter pins upon ™...
Page 158: A-Arm Replacement
BODY / STEERING / SUSPENSION A-Arm Replacement Vehicle Frame Bolt - 30 ft.lbs. (41 Nm) ™ Apply Loctite to the bolt threads. Ball Joint Stud Bushing 8 ft.lbs. (11 Nm) A-Arm Tube 30 ft.lbs. (41 Nm) A-arm Shaft 25 ft.lbs. (35 Nm) Cotter Pin - (Install New) Elevate and safely support vehicle with weight removed from front wheel(s).
Page 159: Ball Joint Replacement
BODY / STEERING / SUSPENSION Ball Joint Replacement Install puller guide (G) with extension cap (H). Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal. for this procedure. 10.
Page 160: Steering Post Removal
BODY / STEERING / SUSPENSION Steering Post Removal SUSPENSION Remove the front cab. Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar. Remove the fuel tank bracket assembly. Hold strut rod and remove top nut. Remove the steering tie rod ends from the steering bracket.
Page 161: Strut Assembly
BODY / STEERING / SUSPENSION Strut Assembly Nut - 15 ft.lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Strut Upper Pivot Ball Spacer Nut Clamp Lower Pivot Ball Washer 18 ft.lbs. (25 Nm) Spring Retainer 15 ft.lbs. (21 Bolts Spring Brake Caliper Hubstrut Bearing Retaining Ring...
Page 162: Sportsman Rear Suspension Assembly
BODY / STEERING / SUSPENSION Sportsman Rear Suspension Assembly 17 ft.lbs. (24 Nm) Stabilizer Bar 35 ft.lbs. (48 Nm) ft.lbs. (48 Nm) ft.lbs. (41 Nm) 35 ft.lbs. (48 Nm) Bushings Upper Control Arm 50 ft.lbs. Rear Shock (68 Nm) Lower Control Arm 30 ft.lbs.
Page 163: X2 Rear Suspension Exploded View
BODY / STEERING / SUSPENSION X2 Rear Suspension Exploded View Rear Compression Spring Preload Adjustment Cam Rear Shock Bushings Control Arm Pivot Bracket Upper Control Arm Boot Shield A-Arm Shaft Lower Control Arm Wheel Bearing Carrier Grease Zerk 5.23...
Page 164: X2 Torsion Bar Exploded View
BODY / STEERING / SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing Stabilizer Bar Stabilizer Bushing Bushing Torsion Mount Linkage Asm. 5.24...
Page 165: X2 Cargo Box
BODY / STEERING / SUSPENSION X2 CARGO BOX Exploded View 5.25...
Page 166: Removal / Installation
BODY / STEERING / SUSPENSION Removal / Installation Disconnect the two wire harnesses connected to each of the taillights. IMPORTANT: Before attempting to remove the cargo box, be sure that the cargo box is not set up for 2-UP riding. The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position.
Page 167 BODY / STEERING / SUSPENSION Lift up firmly in the cargo box release lever on either side Carefully remove the cargo box from the ATV. of the ATV. 10. Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly.
Page 168: X2 Seat Assembly
BODY / STEERING / SUSPENSION X2 SEAT ASSEMBLY Exploded Views 5.28...
Page 169: X2 Seat Operation - Configuring Cargo Box For Passenger Riding
BODY / STEERING / SUSPENSION X2 Seat Operation - Configuring Cargo Box Fold the driver seat backrest down into place to serve as the For Passenger Riding passenger seat bottom. Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below.
Page 170: Driver Seat Backrest Removal / Installation
BODY / STEERING / SUSPENSION Driver Seat Backrest Removal / Installation Lift up on the latch for the passenger seat bottom and lock it in the upright position as shown below. Configure the seating for 2-UP riding. With the passenger seat bottom in place, remove the two screws retaining the seat bottom.
Page 171 CLUTCH SYSTEM CHAPTER 6 CLUTCH SYSTEM SPECIAL TOOLS AND SPECIFICATIONS ........6.2 SPECIAL TOOLS .
Page 172: Special Tools And Specifications
CLUTCH SYSTEM SPECIAL TOOLS AND Component Fastener Torques SPECIFICATIONS Special Tools OMPONENT Drive Clutch Retaining Bolt ESCRIPTION UMBER Driven Clutch Retaining Clutch Puller 2870506 Bolt PVT Inner Cover Bolts Clutch Holding Wrench 9314177 Drive Clutch Spider EBS Clutch Holding Fixture 2871358 Clutch Spider Nut Socket...
Page 173: Pvt Exploded Views
CLUTCH SYSTEM PVT EXPLODED VIEWS PVT Sealing And Ducting Components Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Seal Cover Seal Retainer Bracket Clutch Cover Drive Clutch Exploded Views (Standard and Deluxe) One Way Clutch “Deluxe”...
Page 174 CLUTCH SYSTEM Driven Clutch Exploded Views (Standard and Deluxe) STANDARD - NON EBS DELUXE - EBS 1. Torx Screw 11. Moveable Sheave 2. Cam Assembly 12. Roller Pin 3. Retaining Ring 13. Spring Pin 4. E-clip 14. Stationary Sheave 5. Washer 15.
Page 175: Engine Braking System (Ebs) Exploded View
CLUTCH SYSTEM Engine Braking System (EBS) Exploded View One Way Clutch Drive Washer Drive Belt Washer Shift Weights Cam Assembly Roller/Bushing Retaining Ring Assembly - Torque 200 ft.lbs. Spacer Clutch Rollers Spider Assembly Spider Lock Nut Compression Spring Bushing Cover Clutch Shaft Coil Spring Spacer Washer...
Page 176: Pvt System
During the continually shifting to maintain optimum engine RPM. At full development of a Polaris ATV, the PVT system is matched first throttle a perfectly matched PVT system should hold engine to the engine power curve; then to average riding conditions and RPM at the peak of the power curve.
Page 177: Ebs Clutch Operation
CLUTCH SYSTEM EBS Clutch Operation PVT Maintenance / Inspection This EBS driven clutch provides the same engine braking Under normal operation the PVT system will provide years of abilities as the EBS drive clutch. trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance.
Page 178: Drive Clutch Spring
CLUTCH SYSTEM Drive Clutch Spring Measuring Spring Length: With the spring resting on a flat surface, measure its free length from the outer coil surfaces as shown. Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another.
Page 179: Optional Shift Weights
CLUTCH SYSTEM Optional Shift Weights Shown below are optional shift weights which may be used in the PVT system. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.
Page 180: Pvt Drying
CLUTCH SYSTEM PVT Drying PVT Disassembly IMPORTANT: If operating the ATV through water, be NOTE: Some fasteners and procedures will vary. sure to check the PVT cover and other ATV Refer to the appropriate parts manual for proper components for water ingestion. The ATV should be fasteners and fastener placement.
Page 181: Pvt Installation
CLUTCH SYSTEM PVT Installation Remove driven clutch offset spacers from the transmission input shaft. NOTE: Remember to keep spacers in order for Inspect PVT inner cover-to-engine seal. Replace if proper clutch offset on reassembly. cracked or damaged. Align the alignment mark on the cover with the mark on the engine seal.
Page 182: Drive Belt Removal / Inspection
CLUTCH SYSTEM Drive Belt Removal / Inspection Install clutch offset spacer(s) on transmission input shaft. Remove outer PVT cover as described in PVT Offset Spacer Disassembly. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read.
Page 183: Drive Belt Installation
CLUTCH SYSTEM DRIVE BELT INSTALLATION Measure the distance where the side straight edges intersect the top, as shown in the illustration. NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV.
Page 184: Clutch Alignment
CLUTCH SYSTEM Clutch Alignment Measure belt deflection and measure offset both above and below shaft centerlines. Adjust if necessary. Remove belt and install the Clutch Offset Alignment Tool (PN 2872292) as shown. Center Line Offset Alignment Tool (PN 2872292) Measure Above and Below Centerline 1/8”...
Page 185: Ebs Drive Clutch Service
CLUTCH SYSTEM EBS DRIVE CLUTCH SERVICE Remove and inspect spring. See “Drive Clutch Spring Specifications” for spring inspection. Drive Clutch Disassembly Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast- in X's may not have been in alignment before disassembly.
Page 186 CLUTCH SYSTEM NOTE: It is important that the same number and Inspect all rollers, bushings and roller pins by pulling a flat thickness of washers are reinstalled beneath the metal rod across the roller. Turn roller with your finger. If spider during assembly.
Page 187: Button To Tower Clearance Inspection
Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures Button to Tower Clearance: .000-.001 outlined in this manual.
Page 188: Moveable Sheave Bushing Inspection
CLUTCH SYSTEM Moveable Sheave Bushing Inspection Lift one-way clutch (3) and thrustwasher (4) off shaft. Replace as an assembly if worn, damaged, or if problems Inspect the Teflon™ coating (arrow) on the moveable sheave were noted. bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking.
Page 189 CLUTCH SYSTEM NOTE: Bushings are installed at the factory using Drive Clutch Bushing Installation ™ Loctite 609. In order to remove bushings it will be Place main adapter (Item 8) on puller. necessary to apply heat evenly to the area around ™...
Page 190: One-Way Clutch Inspection (Drive Clutch)
CLUTCH SYSTEM One-Way Clutch Inspection (Drive Clutch) Cover Bushing Removal Install main adapter (Item 8) on puller. Rotate one-way clutch clockwise (as viewed from the cover plate side). The clutch should rotate on the shaft Removal Tool (3) with only slight amount of drag. Verify there is no binding Nut (C) or rough spots.
Page 191 CLUTCH SYSTEM C) “X”, or the marks that were made earlier under weight Install limiter nut on top of spider using the Clutch Spider Nut Socket (PN 2870338). Torque to specification. Reinstall shift weights using new lock nuts on the bolts. Spider Nut Torque: 15 ft.
Page 192: Ebs Driven Clutch Service
CLUTCH SYSTEM EBS DRIVEN CLUTCH SERVICE Place the clutch into Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, Press down on top of the spider assembly, compressing the Driven Clutch Disassembly spider onto the shaft. Remove snap ring (A) and slowly Remove driven clutch from the transmission input shaft.
Page 193 CLUTCH SYSTEM Remove the inside spider plate (D) and spider dampener 10. Pull out the clutch roller pins (L) and rollers (M). (E). Inspect the spider dampener (E) for wear and replaced if needed. Remove the E-clip (F), washer (G), and the clutch rollers (H).
Page 194: Driven Clutch Bushing Removal/Installation
CLUTCH SYSTEM Table 6-1: 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed. To remove the bearing, simply press the bearing from the shaft. ESCRIPTION 13. Inspect the bearing for wear. Spin the bearing, if the Bushing Replacement Kit 2871226 bearing does not spin smoothly replace as needed.
Page 195: Ebs Driven Clutch Reassembly
CLUTCH SYSTEM Driven Clutch Bushing Installation EBS DRIVEN CLUTCH REASSEMBLY Install puller adapter (Item 10) onto puller. Press a new bearing onto the output shaft using a press. Install adapter (Item 9) onto puller. Install the shaft/bearing into the outer sheave. Apply Loctite™...
Page 196 CLUTCH SYSTEM Install the small and large retaining rings into the outer Install the roller (A) onto the roller pin (B). (Both Sides). sheave above the bearing. Install the roller pin into the sheave assembly. (Both sides). The flat side of the roller pin faces downward when the shaft side is laying flat on the bench.
Page 197 CLUTCH SYSTEM Install the spacer washer. 12. Install the spider assembly onto the shaft with the retaining ring on top of the spider. NOTE: Use the marks previously Install Spacer Washer made to align the skip tooth spider, or use the “X” on top of the spider and align it with the skip tooth on the shaft.
Page 198: Standard Drive Clutch
CLUTCH SYSTEM STANDARD DRIVE CLUTCH 15. Install the cam assembly (helix) over the shaft. Line up the “X” on the cam, “X” on spider, and “X” on the stationary sheave or use the marks previously made before Drive Clutch Disassembly disassembly.
Page 199: Spider Removal
CLUTCH SYSTEM ™ Spider Removal Inspect the Teflon coating on the moveable sheave bushing. Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338. Install clutch in holding fixture and loosen the spider (counterclockwise) using Clutch Spider Install Tool PN 2870341.
Page 200: Button To Tower Clearance Inspection
Button to Tower Clearance: .000-.001 All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Inspect sheave surfaces. Replace the entire clutch as an Dealer (MSD) technician who has received the assembly if worn, damaged or cracked.
Page 201 CLUTCH SYSTEM Sheave / Bushing Inspection NOTE: Bushings are installed at the factory using ™ Loctite 609. In order to remove bushings it will be Inspect the Teflon™ coating on the sheave bushings and cover necessary to apply heat evenly to the area around bushing.
Page 202: Drive Clutch Reassembly
CLUTCH SYSTEM Drive Clutch Reassembly Drive Clutch Bushing Installation Place main adapter on puller. NOTE: It is important that the same number and Apply Loctite™ 609 evenly to bushing bore inside thickness of washers are reinstalled beneath the moveable sheave. spider during assembly.
Page 203 CLUTCH SYSTEM Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification. Spacer Washers Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Verify spider spacer washers are fully seated in the recessed area of the spider. Any misalignment will alter clutch balance.
Page 204: Standard Driven Clutch
CLUTCH SYSTEM STANDARD DRIVEN CLUTCH Separate the clutch sheaves by pulling upward while rotating the inner sheave. Disassembly Using special tool PN 8700220, apply and hold downward pressure on the outer spring retainer and remove the snap ring (A). Inspection Inspect both the inner and outer sheave surfaces.
Page 205: Assembly
CLUTCH SYSTEM Assembly Inspect the rollers in the stationary sheave for signs of wear. Install inner spring retainer (if removed). Install the inner sheave onto the outer sheave. NOTE: Verify ‘X’ marks on each side of the sheaves are aligned upon reassembly of sheaves. NOTE: Rollers and helix are non-serviceable items.
Page 206: Pvt Troubleshooting
During this procedure, the throttle should not be held at the full position for more than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Inspection/repair of clutch components should be performed by a certified Polaris MSD Clutch malfunction.
Page 207: Problem, Cause And Remedy Chart
CLUTCH SYSTEM Problem, Cause and Remedy Chart Table 6-2: Problem, Cause and Remedy ITUATION OSSIBLE AUSE EMEDY -Wrong or broken drive clutch spring. -Replace with recommended spring. Engine RPM below specified operating range -Install correct shift weight kit to match engine -Drive clutch shift weight too heavy.
Page 208 CLUTCH SYSTEM Table 6-2: Problem, Cause and Remedy ITUATION OSSIBLE AUSE EMEDY -Abuse (continued throttle application when -Caution operator to operate machine within vehicle is stationary, excess load) guidelines. -Vehicle operated with park brake on. Inspect brake Belt burnt, thin spots -Dragging brake system.
Page 209 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIFICATIONS ............7.2 TORQUE TABLE .
Page 210: Specifications
F/R Aluminum Wheel Nuts w/ ADC Premium Hub Fluid (Deluxe Models) 9.3 oz. (275 ml) Front Hub Nut ADC Gearcase Polaris ADC or AW ISO 10 Rear Hub Nut Pump Reservoir Hydraulic Fluid Front Gearcase Mount Bolts AGL Synthetic or ADF Rear Gearcase Standard Gearcase Screws 5.0 oz.
Page 211 FINAL DRIVE Remove hub. 10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. 11. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.
Page 212: Installation
FINAL DRIVE Installation FRONT DRIVE SHAFT (CV) BOOT Install new spring ring on drive shaft. Apply an anti-seize Inspection compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft Check the front and rear driveshaft CV boots for any tears or leaking grease.
Page 213 FINAL DRIVE Disconnect A-arm from ball joint using a tie rod fork. Remove small clamp and boot from driveshaft. NOTE: If the ATV has been operated with a damaged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary.
Page 214: Front Hub
FINAL DRIVE 13. Install the small clamp on the boot. punch in the reliefs as shown. Front Shaft NOTE: Drive bearing out evenly by tapping on outer FRONT HUB race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
Page 215: Prop Shaft - Front Or Rear
FINAL DRIVE PROP SHAFT - FRONT OR REAR U-JOINT Removal and Installation Disassembly Using Roll Pin Removal Tool (PN 2872608), remove the CAUTION roll pin from prop shaft at rear of housing (front only) or transmission output shaft (rear only). Slide prop shaft back and away from housing, then pull sharply forward to Always wear eye protection when working with remove from transmission shaft.
Page 216: Assembly
FINAL DRIVE Assembly Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing ca Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint.
Page 217 FINAL DRIVE Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
Page 218: Drive Axle Exploded Views
FINAL DRIVE DRIVE AXLE EXPLODED VIEWS Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Circlip Inner CV Joint Circlip Inner Boot Outer Boot Outer CV Joint Circlip Clamps Drive Boot Replacement Kits Clamp 3.5 oz.
Page 219: Front Gearcase - Centralized Hilliard (Standard Models)
FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS) Exploded View (Standard Models) Ref. # Description Ref. # Description Bolt Vent Tube Oil Seal Plug Input Cover Plate Asm. Gearcase Sub Asm. O-Ring Ring Gear / Clutch Housing Retaining Ring Output Hub Asm.
Page 220: Operation
FINAL DRIVE Operation Rollers Engaging front gearcase: The AWD switch may be turned on or off while the vehicle is moving. AWD will not enable until the engine rpm is below 3100 RPM. Once enabled, the AWD Ring Gear remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction.
Page 221: Disassembly / Inspection
FINAL DRIVE Remove cotter pin, lower ball joint nut and A-arm from Remove bolts securing the bottom of housing to the skid ball joint. plate frame. Bolts and fluid drain plug are accessible through the skid plate. Pull the hub and strut assembly out and pull the drive-shaft out of the hub.
Page 222 FINAL DRIVE Remove bolts retaining the outer cover plate assembly. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged Output Hub Assembly Armature Plate...
Page 223 FINAL DRIVE Remove the LH output hub. Inspect the bearing and Inspect roll cage (B) sliding surface. This surface must be contact surfaces of the output hub for signs of wear or clean and free of nicks, burrs or scratches. Inspect the H- damage.
Page 224 FINAL DRIVE 11. Inspect the magnetic coil (A) in the outer cover plate 13. Remove the snap ring retaining the input shaft assembly. assembly. Inspect the backlash pad (B) for excessive wear. 14. Remove the input shaft assembly. Inspect the pinion gear (C) for chipped, broken, or missing teeth.
Page 225: Reassembly / Inspection
FINAL DRIVE Reassembly / Inspection Install the LH output hub (A) into the gearcase housing. The output hub should spin freely. Replace all O-rings, seals, and worn components. Install the RH output hub (B) into the output cover. The Press the pinion shaft seal into the pinion cover, until the output hub should spin freely.
Page 226: Setting Ring Gear Backlash
FINAL DRIVE Install the ring gear and roll cage assembly into the 11. Torque the cover plate bolts to specification. gearcase housing. Install the armature plate on top of the roll cage / ring gear assembly. Be sure that the armature plate tabs are fully engaged into the roll cage assembly.
Page 227: Front Gearcase Diagnosis
FINAL DRIVE Using a 3/32 hex wrench, turn the back-lash screw out 3-4 NOTE: To test the gearcase coil resistance, use the ™ coil harness. The gearcase coil should measure turns. Re-apply Loctite 262 onto the bottom screw threads. between 22.8 ohms and 25.2 ohms. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn.
Page 228: Gearcase Installation
FINAL DRIVE Gearcase Installation Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil To install gearcase, reverse removal procedures. Use new should be seated below the U-shaped insert. The U-shaped roll pin in front prop shaft.
Page 229: Front Gearcase - Active Descent Control (Deluxe Models)
FINAL DRIVE FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS) ADC Gearcase Exploded View (Deluxe Models) Ref. # Description Ref. # Description O-ring Roll Cage Assembly " " Tubing 8-32 x 3/8 Screws 1/4-20 Screws Spacer, Gear Armature Plate Pump Assembly Bushing Wire Connector Vent...
Page 230: Operation
FINAL DRIVE Operation ADC Engagement: When the AWD switch is activated, a 12 Vdc current is present at the input shaft coil (1). Operation is controlled by the ECU grounding and ungrounding the coil. The Engaging Front Gearcase: Active Descent Control (ADC) is coil’s magnetic field attracts a splined armature plate (2) on the controlled by the ECU and will not enable until the following pinion (input) shaft (4).
Page 231: Adc Coil Testing
Replace as an Begin the bleeding process by filling reservoir to ‘MAX’ assembly if found to be damaged or non-working. line with clean Polaris ADC oil . (AW ISO 10 hydraulic Remove bolts (arrows) retaining the outer cover plate fluid equivalent).
Page 232 FINAL DRIVE Remove the outer cover plate assembly. Remove and Remove the armature plate. Inspect the armature plate for inspect the cover o-ring (1). Inspect thrust bearing (2) for wear, distortion or other damage. Replace component as wear. Replace items as required. required.
Page 233 FINAL DRIVE Remove the ring gear (1) and spacer (2). 12. Inspect roll cage sliding surface (2). This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs (4). Replace any components as required. Remove and inspect the bearing surfaces of the output hub.
Page 234 FINAL DRIVE 14. Inspect the magnetic coil (1) in the outer cover plate 16. Inspect the magnetic coil (1) and bushing in the input cover assembly. Inspect the backlash pad (2) for excessive wear. plate assembly. Replace the input cover seal. 17.
Page 235: Adc Gearcase Piston Replacement Procedure
FINAL DRIVE ADC Gearcase Piston Replacement 19. Remove the snap ring retaining the input shaft assembly. Procedure CAUTION This repair procedure involves the use of compressed air. Safety glasses or a face shield are required. Place ADC Piston Tool PA-48542 on top of the piston. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage (circled) to force piston up and out of the case.
Page 236 FINAL DRIVE Coat new piston and o-rings with a moderate amount of Place ADC Piston Tool PA-48542 on top of the piston and white lithium grease or assembly lube. Coat the edges of the verify alignment of the sight hole (circled) and piston mark piston cavities.
Page 237: Assembly
FINAL DRIVE Assembly Install the eccentric cam assembly (1). Thoroughly clean the gearcase components before beginning reassembly. Install a new seal in the main gearcase halve. Install the input shaft assembly. Install the pinion gear/ bearing assembly (1). Install a new seal and o-ring the input shaft cover (2) prior to reassembly.
Page 238 FINAL DRIVE Install a new seal (1) in the outer cover plate assembly. 10. Install the clutch pack (1), spacer (2) and ring gear (3). Install a new o-ring on the backlash pad (2) stem . NOTE: Align locating pins / holes for installation. NOTE: Ring gear backlash (2) is set at the factory.
Page 239 FINAL DRIVE 13. Install new cover o-ring (1) on the cover plate assembly 15. Place cover assembly on Install bolts (arrows) retaining the and a new passage o-ring (2) on the gear case. outer cover plate assembly and torque to specification. 14.
Page 240: Rear Hub
FINAL DRIVE REAR HUB Remove hub nut, domed washer and flat washer. Removal Place the ATV in Park and lock the parking brake. Remove rear hub cap. Remove hub. Remove cotter pin (A). Loosen the hub retaining nut (B). Loosen the wheel nuts (C). Safely support the rear of the ATV.
Page 241: Disassembly
FINAL DRIVE 11. Remove both lower control arm bolts. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press. 12. Remove bearing carrier. NOTE: Drive bearing out evenly by tapping on outer Disassembly race only.
Page 242: Assembly
FINAL DRIVE Assembly Press bearing into place until outer race bottoms on housing. Support bottom of bearing carrier housing. Start bearing in housing. CAUTION Use an arbor press only on the outer race to avoid bearing damage. Install snap ring into groove. Installation Insert bearing carrier on drive shaft.
Page 243: Rear Drive (Cv) Shaft
FINAL DRIVE REAR DRIVE (CV) SHAFT Removal Lower Control Arm Bolt Torque: Remove rear hub, see “REAR HUB REMOVAL”. 50 ft. lbs. (68 Nm) Remove upper carrier bolt. Tip hub outward and remove Lift bearing carrier until top aligns with upper control arm. shaft from carrier.
Page 244: Service
FINAL DRIVE Service Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced Remove clamps from rubber boot(s) using the CV Boot hammer while holding snap ring open. Clamp Pliers (PN 8700226) (A).
Page 245: Cv Boot Replacement
FINAL DRIVE CV Boot Replacement Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take care not to Remove CV joint from end of shaft. damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on Remove boot from shaft.
Page 246: Installation
FINAL DRIVE INSTALLATION While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw Slide shaft assembly into bearing carrier hub. driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life.
Page 247: Drive Shaft And Cv Joint Handling Tips
FINAL DRIVE REAR GEARCASE Install rear wheel and torque wheel nuts to specification. Removal 80 ft.lbs. (109 Nm) Place ATV on a level surface and place transmission in ‘PARK’. Loosen both rear wheel nuts. Loosen both rear center hub nuts. Lift and safely support rear of ATV so that the rear wheels are off the ground.
Page 248 FINAL DRIVE Remove the shim, thrust button, and thrust button shim Inspect the ring gear for abnormal wear, broken, or chipped from the gearcase. teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed. Remove the input shaft cover and the pinion shaft from the gearcase housing.
Page 249: Reassembly
FINAL DRIVE Reassembly Inspect the pinion shaft bushing for wear. Input Cover Bolt Torque: 25 ft.lbs. (34 Nm) Install the original shim(s), thrust button, and thrust button shims into the gearcase cover. Replace all O-rings, seals, and worn components. Apply Crankcase Sealant (PN 2871557) to surface of case and install cover bolts.
Page 250: Installation
See “Torque Table” on page 7.2. To install the rear gearcase, reverse the removal Re-install gearcase vent line. procedures. Refill the rear gearcase with Polaris Premium Gearcase Pre-install the propshaft onto the transmission and insert Lubricant (PN 2871653). Refer to the “REAR the roll pin.
Page 251: Rear Gearcase Exploded View
FINAL DRIVE Rear Gearcase Exploded View 7.43...
Page 252 FINAL DRIVE NOTES 7.44...
Page 253 TRANSMISSION CHAPTER 8 TRANSMISSION SPORTSMAN..........8.3-8.18 SPORTSMAN X2 .
Page 254 TRANSMISSION NOTES...
Page 255 SPORTSMAN TRANSMISSION CHAPTER 8 SPORTSMAN TRANSMISSION TRANSMISSION EXPLODED VIEW......... 8.4 SPORTSMAN 700/800 EFI TRANSMISSION .
Page 256: Sportsman Transmission
SPORTSMAN TRANSMISSION TRANSMISSION EXPLODED VIEW Sportsman Transmission...
Page 257 SPORTSMAN TRANSMISSION Transmission Exploded View Table ESCRIPTION ESCRIPTION Nylon Lock Nut Output Front Cover Shift Drum Bell Crank Hex Screw Hex Screw Gear Set, Lapped Bevel, 10T/31T Sector Cover Ball Bearing, includes 56, 61, 67 O-ring Spacer Detent Pawl Retaining Ring Compression Spring Center Drive Bearing Cover Shift Shaft...
Page 258: Specificiatons
NOTE: TRANSMISSION ILLUSTRATIONS DEPICTED Linkage Rod WITH PARK LOCK. PARK LOCK IS REMOVED FOR 2007. Lubricant / Capacity Use only Polaris recommended products if possible. Specified Lubricant: Transmission Polaris AGL Gearcase Lubricant Switch (Gallon - PN 2873603) (12 oz. - PN 2873602) Disconnect gear position switch harness.
Page 259: Disassembly
SPORTSMAN TRANSMISSION Disassembly 11. Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins from the front prop shaft and the rear prop shaft. Place the bellcrank in neutral position. Remove the front propshaft. Shift Shaft Cover Remove Roll Pin Detent Pawl Case...
Page 260 SPORTSMAN TRANSMISSION NOTE: It may be helpful to place a mark just above Remove the five bolts that secure the cover. Remove the the keyed spline. Note the raised edge on the detent detent spring (B). gear for reassembly. Remove the shift shaft and detent lever. Mark the detent gear (C) with a white pen.
Page 261 SPORTSMAN TRANSMISSION Remove the upper gear cluster and shift forks. You may 12. Remove the bearing from the reverse shaft using a puller. need to move the assembly back and forth to aid in removal. 13. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog.
Page 262 SPORTSMAN TRANSMISSION 15. Remove the snap ring and washer from the reverse shaft. 19. Use a press to remove the gear from the shaft. 16. Remove low gear (33T) and the needle bearing. 20. Make note of the direction of the gear and hub location. 21.
Page 263 SPORTSMAN TRANSMISSION 22. Slide off the shift dogs and wave springs. 25. Remove the pinion shaft retainer plate and the pinion shaft. 26. Remove the front housing cover screws. 23. Remove the snap ring, washer, gear, and split bearing. 27. Remove the front housing cover, shim, thrust button, and 24.
Page 264: Assembly
SPORTSMAN TRANSMISSION Assembly 28. Remove the shafts as an assembly. Reinstall the chain onto the front output shaft and rear output shaft. 29. Remove the silent chain from the assembly for shaft inspection. Install front and rear output shafts into the case. Note location of hubs 30.
Page 265 SPORTSMAN TRANSMISSION ™ Reinstall the thrust button shim, thrust button, and other Apply Loctite 262 (Red) (PN 2871951) to screw threads shims into the cover. Reinstall cover and torque bolts in a and torque screws to specification. criss-cross pattern in 3 steps to specification. NOTE: Verify case locating pins (knock pipes) are in place.
Page 266 SPORTSMAN TRANSMISSION 10. Slide the reverse shaft assembly through the silent chain. 14. As the engagement dogs are installed onto the shaft, place the wave springs into the spring groove. Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case.
Page 267 SPORTSMAN TRANSMISSION 16. Position the shift forks up and so the the pins point toward 19. Lift the shift rail slightly and rotate the rail/fork assembly the 9 o'clock position, before installing the shift drum so it meshes with the tracks on the shiftdrum. Be sure the assembly.
Page 268 SPORTSMAN TRANSMISSION 24. Place a small amount of grease (PN 2871551) into the 27. Apply Crankcase Sealant (PN 2871557) onto the cover and pocket before installing the sector gear. Install the shift gear case mating surfaces. Install the cover and hand tighten all (16T) on the shift drum shaft.
Page 269: Transmission Installation
NOTE: Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft. 32. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended amount. Refer to Maintenance Chapter 2 for more information.
Page 270: Troubleshooting
SPORTSMAN TRANSMISSION Troubleshooting Check the following items when shifting difficulty is encountered. • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection •...
Page 271 Sportsman X2 Transmission CHAPTER 8 Sportsman X2 Transmission TRANSMISSION EXPLODED VIEWS ........8.20 MOUNTING EXPLODED VIEW .
Page 272: Sportsman X2 Transmission
Sportsman X2 Transmission TRANSMISSION EXPLODED VIEWS X2 Transmission Exploded View = THREAD LOCKING AGENT FOR ALL ‘FT. LBS.’ FASTENERS = THREAD LOCKING AGENT FOR ‘INCH LBS. ‘ FASTENERS 8.20...
Page 273 Sportsman X2 Transmission 8.21...
Page 274: Mounting Exploded View
Sportsman X2 Transmission X2 Mounting Exploded View 8.22...
Page 275: Specifications
Bearing Seal Driver 2871282 (50 mm) Lubrication Specified Lubricant Polaris AGL Fluid Gearcase Capacity Approx. 32 oz. (948ml) Remove PVT outer cover, drive and driven clutches, and the inner PVT cover. (refer to Chapter 6). Refer to Chapter 2 for transmission lubricant service.
Page 276 Sportsman X2 Transmission Remove both rear drive shafts. Brake caliper removal is 14. Remove the middle transmission support bracket (K) required. Do not let calipers hang by the brake line. (See completely from the ATV. Chapters 7 and 9) Remove both upper shock absorber mounting bolts and swing shocks away from the transmission.
Page 277: Transmission Installation
Transmission Installation Reconnect the torsion bar to both lower control arms. Torque to specification. Apply Polaris Premium All Season Grease (PN 2871423) to splines of front output shaft ,install new O–ring in prop shaft. With the help of an assistant, rotate transmission into place Lower Torsion Bar Bolt Torque: 17 ft.lbs.
Page 278: Troubleshooting Checklist
11. Once the PVT system is installed. Tighten all remaining transmission mounting bolts to specification. See page 8.2 17. With the ATV on level ground, add Polaris AGL Gearcase for transmission bolt placement. Lubricant to the proper level. See Chapter 2 for proper fill procedures and Torque Specifications.
Page 279: Transmission Disassembly
Sportsman X2 Transmission Transmission Disassembly Remove the compression spring (7). Place the transmission in the Neutral gear before disassembly. Drain and properly dispose of transmission oil. See Chapter Remove the bellcrank nut (1) and remove the bellcrank (2). Remove the c-clip (3) that holds the gear selector switch (4) onto the shaft and remove the selector switch.
Page 280 Sportsman X2 Transmission 10. Remove all cover bolts. Using suitable pry tools, remove 12. Remove the cam chain tensioner spring (14). Slide the cam the cover using the designated pry points. Tap cover with chain tensioner shoe (15), pins (16), and cam chain soft face hammer to remove.
Page 281 Sportsman X2 Transmission 15. Remove the T27 screws that secure the output gear (21) with a T27 hex socket or driver. Gear Cluster Disassembly 16. Remove the shift drum (22) from the gearcase by moving the drum up and to the right to clear the shift shaft. Reverse Shaft Needle...
Page 282 Sportsman X2 Transmission 22. The reverse shaft should slide out of the silent chain (4) to 26. To disassemble the shift fork rail remove the snap ring (10) separate the assembly. from the end of the shift rail on either side. CAUTION 23.
Page 283 Sportsman X2 Transmission 29. Use a 2 3/8” wrench to loosen and remove the front drive 30. If needed, remove the seal from the front of the snorkel shaft snorkel tube (11). tube. Remove the snap ring (12). 31. Remove the second snap ring (13) and spacer (14) from the Front Drive Snorkel Assembly snorkel shaft.
Page 284: Transmission Assembly
Sportsman X2 Transmission 33. To remove the remaining bearing on the snorkel shaft (15), Inspect the output gear assembly (1), replace bearings if remove the retaining ring and press the bearing off. needed. Inspect the 91T gear for damage, chips, or abnormal worn teeth.
Page 285: Transmission Front Output Shaft Backlash Procedure
Sportsman X2 Transmission Install the output gear assembly. Be sure to properly mesh snorkel shaft counterclockwise to the next notch or 8th notch. the snorkel shaft bevel gear with the output bevel gear. Install the 4 torx screws (2) to secure the output gear assembly into place.
Page 286 Sportsman X2 Transmission Once the gear backlash is found, to install the snorkel lock Assemble the input shaft assembly if previously screw, you may have to rotate the snorkel tube clockwise disassembled. or counterclockwise slightly. This will allow the lock screw Input Shaft Assembly A.
Page 287 Sportsman X2 Transmission Inspect the shift drum for any damage or wear. Inspect the NOTE: To ease assembly use a plastic tie strap to hold the shift forks (D) and the shift drum (C) together during splines of the shift drum. Replace the O-rings on the end of the shift drum and lubricate them before assembly.
Page 288 Sportsman X2 Transmission 10. With all of the components in the correct positions install 12. Install the rear drive differential and drive chain, following the 4 output gear assembly screws. Apply Loctite™ 262 these precautions: (PN 2871952) to the threads of the screws. Torque the •...
Page 289 Sportsman X2 Transmission 14. Lift the leg of the spring up and over the rear pin. The 15. Apply a continuous bead of Crankcase Sealant (3-Bond) tensioner cam will lift the shoe and tension chain. (PN 2871557) to the LH gearcase mating surface and install the cover.
Page 290 Sportsman X2 Transmission 17. Install the shift gear (16T) (G) on the shift drum shaft. 20. Install the compression spring (K). Install the sector gear (F) in the bushing pocket on the left side. Aligning the timing marks on the gears. Timing marks 21.
Page 291 BRAKES CHAPTER 9 BRAKES SPECIFICATIONS ............9.2 TORQUE TABLE .
Page 292: Specifications
BRAKES SPECIFICATIONS Torque Table TORQUE SPECIFICATIONS (Sportsman and X2) ORQUE FT ORQUE Front / Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp Bolts (25 in.lbs.) Hand Master Cylinder Reservoir Cover Screws (7 in.lbs.) 0.79 Brake Line Banjo Bolt 15.0 Brake Line Flared Fittings 12-15 16-21 Brake Disc Bolts...
Page 293: Brake System Exploded Views
BRAKES BRAKE SYSTEM EXPLODED VIEWS X2 System Component Exploded View 1) Master Cylinder Cover Screws: 7 in.lbs. (0.79 Nm) 2) Banjo Style Fitting: 15 ft.lbs. (21 Nm) 3) Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) 4) Brake Switch: 12-15 ft.lbs. (16-21 Nm) *Apply Pipe Sealant to Threads 5) Dual Input Master Cylinder and Bleed Screw: 25-30 in.
Page 294: Sportsman System Component Exploded View
BRAKES Sportsman System Component Exploded View...
Page 295: Brake Caliper Exploded Views
BRAKES BRAKE CALIPER EXPLODED VIEWS Sportsman and X2 Front Caliper Assembly Apply Polaris DOT approved Brake Fluid to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Asm. D. Boot E. Square O-rings F. Piston G.
Page 296: Sportsman Rear Caliper Assembly
Never overfill the The Polaris disc brake system consists of the following reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the components or assemblies: brake lever;...
Page 297: Brake Noise Troubleshooting
/ park brake Educate operator to brake fail applied) When servicing Polaris ATV brake systems, use only Polaris Tighten wheel, hub nuts or DOT-approved brake fluid. Loose wheel hub or bearings replace bearings if worn...
Page 298 25-30 in.lbs. (2.80-3.40 Nm) 10. Repeat procedure Steps 5-9 for the remaining caliper(s). Begin bleeding procedure with the caliper that is farthest 11. Add Polaris DOT-approved Brake Fluid to MAX level from the master cylinder. Install a box end wrench on inside reservoir.
Page 299: Front Master Cylinder
BRAKES 12. Install diaphragm, sight glass, cap and screws. 15. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With Master Cylinder Cap lever firmly applied, lever reserve should be no less than 1/ 2”, (1.3 cm) from handlebar.
Page 300: Front Brakes
BRAKES FRONT BRAKES Place new sealing washers on each side of banjo fitting on the brake line and torque banjo bolt to specification. Pad Removal Torque to 15 ft.lbs. (21 Nm) Sealing Washer Elevate and support the of the ATV. CAUTION Banjo Bolt Use care when supporting vehicle so that it does not...
Page 301: Assembly
Assembly edge. Remove inner pad. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
Page 302: Brake Burnishing Procedure
BRAKES Compress mounting bracket and make sure dust boots are Install the adjuster screw and turn clockwise until fully seated. Install pads with friction material facing each stationary pad contacts disc, then back off 1/2 turn other. (counterclockwise). Verify fluid level in reservoir is up to MAX line inside WARNING reservoir and install reservoir cap.
Page 303: Removal / Replacement
BRAKES Removal / Replacement Measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond NOTE: To reduce the possibility of warping, service limit. removing the brake disc mounting bolts before applying heat to the bolts. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent.
Page 304: Front Caliper
BRAKES FRONT CALIPER Remove mounting bracket, pin assembly and dust boot. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. Loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line.
Page 305: Inspection
Coat piston with clean Polaris DOT-approved Brake Fluid = In. / mm. (C). Install piston (D) with a twisting motion while pushing inward.
Page 306: Installation
BRAKES Compress the mounting bracket and make sure the dust Install brake line and torque the banjo bolt to specification. seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
Page 307: Rear Brake Pad
BRAKES REAR BRAKE PAD Push caliper piston into the caliper bore slowly using a C- clamp or locking pliers with pads installed. X2 Pad Removal Elevate and support the rear of the ATV. Remove the rear wheel Loosen pad adjuster screw 2-3 turns. NOTE: Brake fluid will...
Page 308: X2 Pad Installation
Maintain at least 1/2, (12.7 mm) of brake fluid in the Lubricate mounting bracket pins with a light film of reservoir to prevent air from entering the brake system. Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Install the adjuster screw and turn clockwise until the stationary pad contacts the disc, then back off 1/2 turn (counterclockwise).
Page 309: Sportsman Rear Pad Removal
BRAKES Sportsman Rear Pad Removal NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink Support the machine. Remove the rear tire. or bend brake line. Remove the slide pin clips from the slide bolt. Push caliper pistons into caliper bore slowly with pads installed.
Page 310: Sportsman Rear Pad Installation
BRAKES Sportsman Rear Pad Installation Install the slide bolt snap ring. Torque the slide pin to specification. Install new brake pads in caliper body. Install Pads 30-35 ft.lbs. (41-48 Nm) WARNING Caliper Slide Bolt Torque: If the brake pads are contaminated with grease, 30-35 ft.lbs.
Page 311: X2 Rear Caliper
BRAKES X2 REAR CALIPER Remove piston, dust seals and piston seals. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. Clean caliper area before removal. Place a container below the caliper to catch brake fluid that will drain from the brake line.
Page 312: Inspection
Rear Caliper Piston Bore I.D. Service Limit: 1.193” (30.30 mm) Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber Inspect piston for nicks, scratches, wear or damage. dust seal boots.
Page 313: Sportsman Rear Caliper
BRAKES Compress the mounting bracket and make sure the dust Remove the slide bolt snap rings (A), the slide pins (B), the seals are fully seated. Install the brake pads. Clean the disc bracket pad (C), and the brake pads (D). and pads with brake parts cleaner or denatured alcohol to Caliper remove any dirt, oil or grease.
Page 314: Assembly
BRAKES Assembly Measure the inside diameter of the rear caliper. The caliper body is a 2-step piston. The rear step is measured as well Install new O-rings in the slide bolt bushing holes. Be sure as the outside step. O-ring and seal grooves are thoroughly cleaned of all residue, or piston may bind in bore.
Page 315: Rear Brake Disc
BRAKES REAR BRAKE DISC NOTE: The slide pins should be torqued when installed on caliper mount. Inspection Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a micrometer and measure disc thickness at 8 different points around perimeter of disc.
Page 316: Rear Master Cylinder
BRAKES REAR MASTER CYLINDER X2 Exploded View A. Master Cylinder Bolts B. Rear Brake Line C. Rear Master Cylinder D. Bushing(s) E. Washer(s) F. Cotter Pin G. Foot Pedal H. Spring I. Front Brake Line J. Banjo Fitting 9.26...
Page 317: Overview
If required, remove the rear brake line from the master cylinder. Use a suitable container to catch the brake fluid. Polaris disc brake systems are light weight, low maintenance Dispose of brake fluid properly. and perform well in the conditions ATV’s routinely encounter.
Page 318: Sportsman Rear Master Cylinder Removal / Installation
BRAKES Sportsman Rear Master Cylinder Removal / Reinstall the brake line and torque the banjo bolt to Installation specification depending on the style of fitting. Remove the RH footwell to gain access to the rear master cylinder. Remove the rear brake lines from the master cylinder. Use Banjo Bolt Torque: a suitable container to catch the brake fluid.
Page 319: Pedal Removal And Installation
BRAKES Pedal Removal and Installation TROUBLESHOOTING Brakes Squeal • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn disc splines X2 Shown Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned Remove the RH footwell to gain access to the rear master •...
Page 320 BRAKES NOTES 9.30...
Page 321 ELECTRICAL CHAPTER 10 ELECTRICAL INSTRUMENT CLUSTER ..........10.3 OVERVIEW.
Page 322 ELECTRICAL LIGHTING ............10.26 HIGH BEAM HEADLIGHT BULB REPLACEMENT .
Page 323: Instrument Cluster
Introduction Refer To Illustration 1: Overview The Polaris ATV Instrument Cluster is powered by battery (A) Speedometer Needle (flashes during warning condition) voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and speed sensor for proper operation. Two (B) Speedometer harnesses plug into the cluster head;...
Page 324: Instrument Cluster Diagnostic Mode
ELECTRICAL Instrument Cluster Diagnostic Mode 4. High/Low Battery Voltage • This warning usually indicates that the ATV is being NOTE: This gauge features auto shut-off protection operated at an RPM too low to keep the battery if the voltage on the DC bus is excessive. This is charged.
Page 325 ELECTRICAL Screen 2 - Tachometer: (Ill. 3) indicates engine rpm. NOTE: 10--20% Variance from these reading is within normal parameters. Ill.3 23 Ohms in Park Screen 3 - AWD Diagnostic Screen: This screen indicates whether or not current is flowing through the AWD coil on models with AWD.
Page 326: Setting A New Service Interval
ELECTRICAL Setting A New Service Interval While in the service interval mode, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed.
Page 327: Efi Diagnostic Mode
NOTE: The EFI diagnostic mode is intended to displayed. quickly view fault codes stored in the EFI module. Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink code. To download blink codes (failure codes) from you EFI module: Be sure the ATV key switch is off and with the shifter is in Park.
Page 328: Speedometer Removal
ELECTRICAL Speedometer Removal Remove the three screws that secure the headlight pod LINK AILURE ESCRIPTION cover and disconnect the wire connectors from the instrument cluster. No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery...
Page 329: Speedometer Installation
ELECTRICAL Speedometer Installation Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the pod assembly more easily. Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway.
Page 330: Speedometer Troubleshooting
ELECTRICAL SPEEDOMETER TROUBLESHOOTING Test 1 - No All Wheel Drive 10.10...
Page 331: Test 2 - No Display / Test 3 - No Reverse Speed Limit
ELECTRICAL TEST 2 - No Display / TEST 3 - No Reverse Speed Limit 10.11...
Page 332: Test 4 - No Awd Hub Safety Limiter
ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.12...
Page 333: Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
ELECTRICAL TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor 10.13...
Page 334: Test 7 - No Fuel Gauge / Test 8 - Transmission Switch
ELECTRICAL TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch 10.14...
Page 335: Active Descent Control (Adc) Coil
ELECTRICAL ACTIVE DESCENT CONTROL (ADC) ALL WHEEL DRIVE (AWD) COIL COIL Operation Overview Operation Overview • AWD switch must be ‘ON’. 12Vdc power is present at the ADC hub coil. • AWD switch must be ‘ON’. 12Vdc power is present at the ADC hub coil.
Page 336: Cooling System Components
ELECTRICAL COOLING SYSTEM COMPONENTS Coolant Temperature Sensor The coolant temperature sensor can be tested using an ohmmeter Fan Control Circuit Operation / Testing or voltmeter. Power is supplied to the fan via the Orange/Black wire when the With the engine and temperature sensor at room relay is ON.
Page 337: Fan Motor Current Draw
ELECTRICAL Fan Motor Current Draw GEAR POSITION INDICATOR SWITCH A current draw test will provide a good indication of fan motor Test Diagram condition. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced NOTE: Also see “INSTRUMENT CLUSTER cooling.
Page 338: Electronic Throttle Control (Etc) Switch
ELECTRICAL ELECTRONIC THROTTLE CONTROL functioning properly, the engine will lose spark and stop. (ETC) SWITCH Electronic Throttle Control (ETC) Switch (Composite Throttle Housing) ETC Switch Operation The Electronic Throttle Control (ETC) system is designed to ETC Switch contacts are stop the engine of an ATV in the event of a mechanical problem closed in a fault condition with the throttle mechanism.
Page 339: Ignition System
ELECTRICAL IGNITION SYSTEM Flywheel Identification The flywheel can be identified by the stamp mark in location A. Refer to I.D." location in chart below. Do not use the cast mark to determine flywheel application. Kokusan Flywheel Timing Marks Production Date Part Number Engine Application Cast...
Page 340: Alternator/Ignition Components - 700/800 Efi
ELECTRICAL Alternator/Ignition Components - 700/800 EFI Ignition Coils Battery to Solenoid Cable Starter Solenoid Cable 30 Amp/hr. Battery Coil Wires Solenoid Switch (starter) Control Module Relays Fuses Negative Battery Cable Spark Plugs Pre-Wire Winch Cables Voltage Regulator Stator Assembly Flywheel Crank Position Sensor 10.20...
Page 341: Crankshaft Position Sensor Gap
ELECTRICAL Crankshaft Position Sensor Gap CHARGING SYSTEM Measure trigger coil gap with a feeler gauge. The gap should be Current Draw - Key Off .059 inch (1.0 mm). CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components.
Page 342: Charging System "Break Even" Test
ELECTRICAL Charging System “Break Even” Test Alternator Output Test Three tests can be performed using a multimeter to determine CAUTION the condition of the stator (alternator). Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components.
Page 343 ELECTRICAL TEST 2: Resistance Value of Stator Leg to Ground Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. NOTE: Any measurement other than Infinity (open) will indicate a failed or shorted stator leg. TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM Set the selector dial to measure AC Voltage.
Page 344: Charging System Testing Flow Chart
ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. Using a multitester set on D.C. volts, measure the battery open circuit voltage (See earlier test).
Page 345: Relays
ELECTRICAL RELAYS POWER RELAY Operation OLOR UNCTION KEY-ON Battery power supply, switched The relays, located next to the ECU, assist with component operation such as the fan, fuel pump, etc. on by the key and LH control switches, Red/White enables power to relay. Tied to Fan Relay The fan relay, controlled by the ECU, operates the fan.
Page 346: Fuses/Circuit Breaker
ELECTRICAL FUSES/CIRCUIT BREAKER LIGHTING Operation High Beam Headlight Bulb Replacement The fuse panel, located next to the ECU, assist with component protection such as the Instrument Cluster/ECU, EFI system, Chassis Power and Accessories. A 20-amp circuit breaker protects the fan circuit. Remove 3 Screws CAUTION Do not service while headlight is hot.
Page 347: Headlight Housing Replacement
ELECTRICAL Turn the headlight lamp socket counter-clockwise and Unplug headlamp harness (C). remove. Turn Harness Assembly Loosen Tighten Remove O-Ring (D) from headlight pivot pins. (Both Carefully remove headlamp bulb from housing. Sides) Remove the headlamp and replace with a new headlamp. NOTE: Do not touch the lamp with bare fingers.
Page 348: High Beam Headlight Adjustment
ELECTRICAL Reverse the steps to install the new housing and reassemble Place the vehicle on a level surface with the headlight the pod. approximately 25' (7.6 m) from a wall. 25’ (7.6 m) Lamp Center Height 2” (5.1 cm) 5 1/8” (13 cm) NOTE: The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1/8”, (13 Measure the distance from the floor to the center of the...
Page 349: Low Beam Headlight Adjustment
ELECTRICAL Low Beam Headlight Adjustment Pull the harness assembly out from the headlight assembly. The low beam can be adjusted slightly upward or downward. Loosen Screw Remove the lamp and replace with a new headlamp. NOTE: Do not touch the new lamp with bare fingers. Hold the plastic part (1) of the lamp.
Page 350: Sportsman Work Light Switch (Deluxe)
ELECTRICAL Sportsman Work Light Switch Sportsman Brake Light / Work Light (Deluxe) (Deluxe) Replacement Remove the headlight pod cover to locate the switch wires. The switch snaps out by pushing in on the tabs on both sides of the The brake light (A) and the work light (B) are both located in the switch.
Page 351: X2 Brake Light / Work Light (Deluxe) Replacement
ELECTRICAL X2 BRAKE LIGHT / WORK LIGHT To remove the brake light electrical connector (B), press in (Deluxe) REPLACEMENT on the tab on the connector to unlock the connector and pull the connector from the bulb assembly. The brake light (A) and the work light (B) are both located in the rear tail lamp housing.
Page 352: Brake Light Switch
ELECTRICAL Brake Light Switch Carefully pull out the red locking tab on the connector. Remove the front cover. Brake Lamp Switch Once the red tab is pulled out, press in on the black tab and pull out to disconnect harness. Black Tab Red Tab Brake Switch...
Page 353: Fuel Sender
ELECTRICAL FUEL SENDER X2 DIFFERENTIAL SYSTEM Testing Solenoid Testing Drain the fuel tank and remove it from the atv. Disconnect from the wire harness. Using a digital ohmmeter, test the solenoid at the connector leads and compare to the Set the fuel tank on a flat surface. specification.
Page 354: Differential Relay Operation
ELECTRICAL Differential Relay Operation X2 SPEED SENSOR • The AWD switch must be turned to ‘TURF’ mode. Testing • Speed must be below 15mph and transmission must not Using the special tools listed, test the speed sensor according to be in ‘Park’. the tester instructions.
Page 355: Accessory Power
ELECTRICAL ACCESSORY POWER NOTE: Refer to the accessory instructions for accessory hook-up and installation. Wire Connections Winch Installation Orange/White Wires Located In This Area The Sportsman models have the main winch cables routed and installed from the factory. This enables quick installation. Refer to Chapter 2 for more information on winch installation and operation.
Page 356: International
ELECTRICAL STARTER SYSTEM 700/800 Starter Lockout Overview and Diagnostic The Sportsman 700/800 and International EFI starter lockout is controlled by the ECU. Pin #20 senses the transmission signal and determines if the switch is in Neutral or Park. Pin #24 senses when the brake is applied. When the conditions are met, the ECU will activate Pin #16 to ground the starter solenoid.
Page 357: 800 X2 Starter Lockout Overview And Diagnostic
ELECTRICAL 800 X2 Starter Lockout Overview and Diagnostic The Sportsman 800 X2 EFI starter lockout is controlled by the ECU. Pin #20 senses the transmission signal and determines if the switch is in Neutral or Park. Pin #24 senses when the brake is applied. When the conditions are met, the ECU will activate Pin #16 to ground the starter solenoid.
Page 358: Troubleshooting
ELECTRICAL Troubleshooting Starter Motor Removal / Disassembly NOTE: Use electrical contact cleaner to clean starter Starter Motor Does Not Run motor parts. Some solvents may leave a residue or • Battery discharged - Low specific gravity damage internal parts and insulation. •...
Page 359: Brush Inspection / Replacement
ELECTRICAL Remove the front bracket assembly and the rear bracket Measure resistance between insulated brush and starter assembly. Remove the shims from the armature shaft and housing. Reading should be infinite. (OL). Inspect inspect the O-rings located on the armature housing. insulation on brush wires for damage and repair or replace as necessary.
Page 360: Armature Testing
ELECTRICAL Brush Replacement Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no Remove terminal nut with lock washer, flat washer, large continuity). phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
Page 361: Starter Reassembly / Installation
ELECTRICAL Starter Reassembly / Installation Lightly grease pinion shaft and install pinion, spring stopper, and snap ring. Install brush plate to field magnet housing aligning index tab. 10. Install the starter onto the engine case. Hand tighten each of the starter bolts. Torque the bottom bolt first to 9 Install O-ring, two small phenolic spacers, large phenolic ft.lbs.
Page 362: Starter Drive
ELECTRICAL Starter Drive Pinion Gear - Anti-kick Out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and install a new garter spring: A.
Page 363: Starter Exploded View
ELECTRICAL Starter Exploded View Indicates Do not reuse. 10. Gear Assembly 1. Rubber Ring* 11. Through Bolt Replace with new parts. 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6.
Page 364: Starter System Testing Flow Chart
ELECTRICAL STARTER SYSTEM TESTING FLOW CHART 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 With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service.
Page 365: Basic Winch Wiring- Pre-Wired Models
ELECTRICAL BASIC WINCH WIRING- PRE-WIRED MODELS 10.45...
Page 366: Battery
ELECTRICAL BATTERY Battery Activation (Conventional) Battery Identification WARNING NOTE: It is important to identify what type of battery you have installed in your ATV. Different types of Battery electrolyte is poisonous. It contains sulfuric batteries require different service procedures. acid. Serious burns can result from contact with Proper servicing and upkeep of your battery is very skin, eyes or clothing.
Page 367: Battery Terminals/Bolts
1.270 or higher. Battery Terminals/Bolts Terminal Preparation Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) on battery bolts and terminals when installing a battery. This will help to prevent corrosion and maintain good electrical connection.
Page 368: Conventional Battery Testing
ELECTRICAL Install clear battery vent tube from vehicle to battery vent. WARNING Vent tube must be free from obstructions and kinks and Battery Hydrometer (PN 2870836) securely installed. If not, battery gases could accumulate and cause an explosion. The vent tube should be routed away from frame and body to prevent contact with Route the cables correctly.
Page 369: Battery Load Test
ELECTRICAL Battery Load Test NOTE: Recharge to full capacity every 30 to 60 days during a non-use period. If the battery is stored during the winter months, electrolyte will freeze at CAUTION higher temperatures as the battery discharges. The chart below indicates freezing points by specific gravity.
Page 370: Low Maintenance Battery
ELECTRICAL Install clear battery vent tube from vehicle to battery vent. NEW BATTERIES: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3-5 hours using a variable rate charger. Do WARNING not use the alternator to charge a new battery.
Page 371: Low Maintenance Battery Inspection / Removal
ELECTRICAL BATTERY CHARGING REFERENCE TABLE The X2 battery is located under fuel tank and can be accessed by removing the right hand side panel. TATE OF HARGE OLTAGE CTION HARGE None, check voltage at 3 mos. None 100% 12.8-13 V after manufacture Required date...
Page 372: Low Maintenance Battery - Ocv- Open Circuit Voltage Test
ELECTRICAL Low Maintenance Battery - OCV- Open Low Maintenance Battery Load Test Circuit Voltage Test CAUTION Battery voltage should be checked with a digital multitester. Readings of 12.8 volts or less require further battery testing and charging. See charts and Load Test. To prevent shock or component damage, remove NOTE: Lead-acid batteries should be kept at or near spark plug high tension leads and connect securely...
Page 373: Low Maintenance Battery Off-Season Storage
ELECTRICAL Low Maintenance Battery Off-season Low Maintenance Battery Charging Storage Procedure Battery voltage should be checked with a digital multitester. Remove the battery from the ATV to prevent damage from Readings of 12.8 volts or less require further battery testing and leaking or spilled acid during charging.
Page 374 ELECTRICAL NOTES 10.54...
Page 375 800 EFI INTERNATIONAL CHAPTER 11 800 EFI INTERNATIONAL 800 EFI INTERNATIONAL BRAKE SYSTEM ....... . . 11.2 OVERVIEW.
Page 376: 800 Efi International Brake System
800 EFI INTERNATIONAL 800 EFI INTERNATIONAL BRAKE SYSTEM Overview The Sportsman International brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the foot brake and hand brake systems and allows 4 wheel braking from either control separately, or at the same time. When the foot brake is applied, all brake calipers are active, as braking pressure is routed from the foot brake master cylinder through the proportioning valve and distribution block, exiting one line to the front calipers, while the other line exits the proportioning valve and feeds the outer line to the rear calipers.
Page 377 800 EFI INTERNATIONAL Exploded View 11.3...
Page 378: 800 Efi International Steering Post And Lock Assembly
800 EFI INTERNATIONAL 800 EFI INTERNATIONAL STEERING POST AND LOCK ASSEMBLY Steering Assembly Exploded View The 800 EFI International Sportsman is equipped with a locking mechanism to prevent theft or unauthorized use. Steering post removal may be required for lock service or repair. Lock System Item Number / Description: 11.
Page 379: 800 Efi International Electrical
800 EFI INTERNATIONAL 800 EFI INTERNATIONAL ELECTRICAL Turn / Hazard Signal Diagram 11.5...
Page 380 800 EFI INTERNATIONAL NOTES 11.6...
Page 381 Brake System Inspection ......2.26 Brake System Overview, International ....11.2 A-Arm Replacement .
Page 382 Drive Clutch Weights ......6.9 Engine Piston Removal, Inspection ....3.30 Drive Clutch, Operation .
Page 383 Lower Headlamp Removal ..... . 10.28 PVT, Moveable Sheave Inspection ... . 6.18 6.31 Lubricants/Fluids, Polaris Brand Part Numbers ..2.9 Lubricants/Fluids, Polaris Brand Symbol Identification Chart 2.10 Radiator .
Page 384 Rear Gearcase, Installation ..... . .7.42 Specifications, Engine Lubrication ....3.20 Rear Gearcase, Removal .
Page 385 Transmission Mounts, Exploded View ... . . 8.22 Transmission Removal ......8.6 Transmission Troubleshooting .
Page 386 IX.6...
Page 387 WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL (ADC) WIRE DIAGRAM WD-1...
Page 388 WIRE DIAGRAM 2007 SPORTSMAN 700/800 EFI WIRE DIAGRAM WD-3...
Page 389 WIRE DIAGRAM WD-4...
Page 390 WIRE DIAGRAM 2007 SPORTSMAN 800 X2 EFI WIRE DIAGRAM WD-5...
Page 391 WIRE DIAGRAM WD-6...
Page 392 WIRE DIAGRAM 2007 SPORTSMAN 800 EFI INTERNATIONAL WIRE DIAGRAM WD-7...
Page 393 WIRE DIAGRAM WD-8...

This manual is also suitable for:

2007 sportsman 700 x2 efi 2007 sportsman x2 800 efi

Polaris 2007 SPORTSMAN X2 800 Service Manual

General Information Chapter 1 1

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine

Fuel Injection Chapter 4 Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Clutch System Chapter 6 Clutch System

Final Drive Chapter 7 Final Drive

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Chapters

Troubleshooting

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Summary of Contents for Polaris 2007 SPORTSMAN X2 800