Polaris 2008 sportsman touring Manuals

Manuals and User Guides for Polaris 2008 sportsman touring. We have 1 Polaris 2008 sportsman touring manual available for free PDF download: Service Manual

Polaris 2008 sportsman touring Service Manual

Polaris 2008 sportsman touring Service Manual (406 pages)

Atv Polaris 2007 Sportsman 450 / 500 EFI / 500 X2 EFI

Brand: Polaris | Category: Offroad Vehicle | Size: 56.73 MB

Table of Contents

General Information Chapter 1 1

5
Maintenance Chapter 2 Maintenance 2

21
- Chapter 2
  23
- Maintenance
  23
- Maintenance Chart Key
  23
- Periodic Maintenance Chart
  23
- Lubrication / Fluids
  27
- Vehicle Inspection
  34
  - Shift Link Rod Inspection
    34
  - Throttle Inspection
    35
  - Fuel System
    36
  - Fuel Lines
    36
  - Vent Lines
    36
  - Fuel Filter
    37
  - Compression Test
    37
  - Engine Mounts
    37
  - Spark Plug
    38
  - Active Descent Control (Adc) Reservoir Level
    38
  - Battery Maintenance
    38
  - Liquid Cooling System Overview
    39
  - Coolant Strength / Type
    39
  - Cooling System Hoses
    39
  - Radiator/Grill Screen
    39
  - Cooling System Pressure Test
    40
  - Coolant Level Inspection
    40
  - Radiator Coolant Level Inspection
    40
  - Air Filter/Pre-Filter Service
    40
  - Air Box Sediment Tube
    41
  - Breather Filter Inspection
    42
  - Breather Hose
    42
  - Recoil Housing
    42
  - Engine Oil Level
    43
  - Oil and Filter Change
    43
  - Oil Pump Priming Procedure
    45
  - Valve Clearance
    45
  - Intake Valve Clearance Adjustment
    46
  - Exhaust Valve Clearance Adjustment
    46
  - Steering
    46
  - Tie Rod End/Steering Inspection
    47
  - Camber and Caster
    47
  - Wheel Alignment
    47
    
    Brakes
    48
  - Toe Alignment Adjustment
    48
  - Exhaust Pipe
    48
  - Brake System Inspection
    49
  - Brake Pad Inspection
    50
  - Hose/Fitting Inspection
    50
- Auxiliary Brake Adjustment (Hydraulic)
  50
- Auxiliary Brake Testing
  50
- Controls
  51
- CV Shaft Boot Inspection
  51
- Front Suspension
  51
- Suspension Spring Preload Adjustment
  51
- Wheels
  51
- Tire Pressure
  52
- Wheel Installation
  52
- Wheel Removal Front or Rear
  52
- Wheel, Hub, and Spindle Torque Table
  52
- Frame, Nuts, Bolts, Fasteners
  53
- Storage Compartments
  53
- Tire Inspection
  53
- Winch Operation (if Equipped)
  54
- Atv Cleaning & Storage
  56
- Maintenance Schedule
  58
Chapter 3 Engine

59
- Engine Fastener Torque Patterns
  61
- Special Tools
  61
- Specifications
  61
- Torque Specifications
  61
- Engine Service Data
  62
- General Engine Service
  64
  - Piston Identification
    64
  - Cooling System Specifications
    64
  - Cooling System
    65
  - Accessible Components
    66
  - Engine Removal (Typical)
    66
  - Engine Installation Notes
    67
  - Cylinder Hone Selection/ Honing Procedure
    67
  - Honing to Oversize
    67
    
    Electrical
    68
  - Cleaning the Cylinder after Honing
    68
  - Crankshaft Straightening
    68
  - Engine Lubrication-EH 50PL
    69
  - Oil Pressure Test - Eh 50Pl
    69
  - Oil Pump Priming Procedure
    69
  - Oil Flow - Eh50Pl
    69
  - Eh50Pl Oil Flow Diagram
    70
  - Eh50Pl Engine Exploded Views
    71
- Engine Disassembly
  72
  - Cam Chain Tensioner/Rocker Arm/ Camshaft Removal
    72
  - Cam Chain Tensioner Inspection
    72
  - Rocker Arm/Shaft Inspection
    73
  - Camshaft Removal
    74
  - Automatic Compression Release Removal/Inspection
    75
  - Automatic Compression Release Installation
    76
  - Camshaft Inspection
    76
  - Cylinder Head Removal
    77
  - Cylinder Head Exploded View, Eh50Pl
    78
  - Cylinder Head Inspection
    79
  - Cylinder Head Warp
    79
  - Cylinder Head Disassembly
    79
  - Valve Inspection
    80
  - Combustion Chamber
    81
  - Valve Seat Reconditioning
    81
  - Cylinder Head Assembly
    84
  - Valve Sealing Test
    84
  - Valve Clearance Adjustment
    84
  - Cylinder/Piston Removal and Inspection
    85
  - Piston Removal
    86
  - Cylinder Inspection
    86
  - Piston-To-Cylinder Clearance
    87
  - Piston/Rod Inspection
    87
  - Piston Ring Installed Gap
    88
  - Crankcase Disassembly
    88
  - Starter Drive Removal/Inspection
    89
  - Flywheel/Stator Removal/Inspection
    89
  - Cam Chain/Tensioner Blade
    90
  - One Way Valve Removal
    90
  - Crankcase Separation
    91
  - Oil Pump Removal/Inspection
    91
  - Oil Pump Assembly
    92
  - Counter Balancer Shaft Removal/Inspection
    92
  - Crankshaft Removal/Inspection
    93
  - Crankcase Bearing Inspection
    94
  - Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal
    94
  - Crankcase Inspection
    94
  - Bearing Installation
    95
  - End Play Inspection/Adjustment
    95
  - Crankshaft End Play Adjustment
    95
  - Counter Balancer Shaft End Play Adjustment
    96
  - Oil Pump Shaft End Play Adjustment
    97
- Engine Reassembly
  98
  - Pump Shaft Oil Seal Installation
    98
  - Crankshaft/Counter Balance/Oil Pump Installation
    98
  - Crankcase Assembly
    99
  - Water Pump Mechanical Seal Installation
    99
  - Water Pump Mechanical Seal Removal - Engine Installed
    99
  - One Way Valve Installation
    100
  - Cam Chain Drive Sprocket Installation
    101
  - Tensioner Blade Installation
    101
  - Piston Ring Installation
    101
  - Piston Installation
    102
  - Cylinder Installation
    102
  - Cylinder Head Installation
    103
  - Cam Chain/Camshaft Installation
    103
  - Camshaft Timing
    106
  - Cam Chain Tensioner Installation
    107
  - Stator, Flywheel and Starter Drive Installation
    107
  - Rocker Shaft/Rocker Arm Assembly Installation
    108
  - Thermostat Installation
    108
  - Oil Pipes
    108
- Recoil
  109
  - Recoil Disassembly/Inspection
    109
  - Recoil Assembly
    110
- Troubleshooting
  111
  - Spark Plug Fouling
    111
  - Engine
    111
  - Cooling System
    112
Fuel Injection Chapter 4 Fuel Injection

115
- Chapter 4 Part Numbers / Descriptions
  117
- Special Tools
  117
- Efi Service Notes
  119
  - General Service Information
    119
- Efi System Exploded View
  120
- Efi System
  121
  - Component Locations/Identification
    121
- Electronic Fuel Injection
  122
  - General Information
    122
  - Efi Operation Overview
    122
  - Initial Priming / Starting Procedure
    123
- Fuel Tank
  122
  - Exploded View
    122
- Fuel Lines
  123
  - Quick Connect Removal/Installation
    123
- Electronic Control Module (Ecm)
  124
  - Operation Overview
    124
  - Ecm Replacement
    124
  - Ecm Service
    124
- Fuel Pump Assembly
  125
  - Operation / Testing
    125
  - Fuel Pump Test
    125
  - Fuel Pump / Tank Assembly Replacement
    126
- Fuel Pressure Regulator
  127
  - General Information
    127
- Fuel Filters
  128
  - General Information
    128
- Fuel Injector
  128
- Crankshaft Position Sensor (Cps)
  129
  - General Information
    129
  - Fuel Injector Replacement
    129
- Manifold Air Pressure Sensor (Map)
  130
  - Operation Overview
    130
  - Map Sensor Test
    130
  - Crankshaft Position Sensor Replacement
    130
  - Map Sensor Replacement
    130
- Idle Air Control (Iac)
  131
  - General Information
    131
- Intake Air Temperature Sensor (Iat)
  131
- Throttle Position Sensor (Tps)
  132
- Engine Temperature Sensor
  134
  - General Information
    134
  - Engine Temperature Sensor Test
    134
  - Engine Temperature Sensor Replacement
    134
- Fuel System Troubleshooting
  135
  - Fuel Starvation / Lean Mixture
    135
- Efi Diagnostics Using 'Blink Codes
  136
  - Blink Codes - Operation
    136
- Troubleshooting Diagrams
  138
Carburetor - Sportsman 450 Chapter 4 Carburetor - Sportsman 450

143
- Carburetor - Sportsman 450
  144
- General Information and Specifications
  144
  - Special Tools
    144
  - Carburetor Jetting
    144
  - Mikuni Jet Part Numbers
    144
  - Carburetor Specifications
    144
- Carburetion
  145
  - Bst 34 Carburetor Exploded View 1 of 2
    145
  - Bst 34 Carburetor Exploded View 2 of 2
    146
  - CV Carburetor System Function
    147
  - Carburetor Venting
    147
  - Mikuni CV Carb Operation
    147
  - Starter System (Choke or Enrichment)
    148
  - Pilot (Idle and Slow) System
    148
  - Main System
    149
  - Float System
    149
  - Pilot Screw
    150
  - Air/Fuel Mixture Ratio
    150
  - Jet Needle
    151
  - Needle Jet
    151
  - Throttle Opening Vs. Fuel Flow
    151
  - Carburetor Disassembly - Mikuni CV
    151
  - Carburetor Cleaning
    152
  - Carburetor Inspection
    153
  - Carburetor Assembly
    153
  - Float Height Adjustment
    154
  - Needle and Seat Leakage Test
    154
  - Fuel Level Test
    155
- Fuel Tank/Fuel Delivery System
  156
  - Fuel System Exploded View
    156
- Fuel Pump
  157
  - Fuel Pump Testing
    157
  - Fuel Pump Disassembly
    157
  - Fuel Pump Inspection and Reassembly
    158
  - Fuel Filter Replacement
    158
- Fuel Gauge Sending Unit
  158
  - Sending Unit Removal
    158
  - Testing
    159
  - Sending Unit Installation
    159
- Troubleshooting
  159
  - Fuel Starvation/Lean Mixture
    159
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

161
- Chapter 5
  162
- Decal Replacement
  162
- General Information
  162
- Special Tools
  162
- Torque Specifications
  162
- Plastic Insert Removal / Installation
  163
- Body
  164
  - Side Panel Removal
    164
  - Front Cover Removal / Installation
    164
  - Foot Well Removal / Installation
    165
  - X2 Foot Well Removal / Installation
    165
  - Front Storage Removal
    166
  - Front Storage Installation
    168
  - Sportsman Rear Rack Removal / Installation
    168
  - Front Cab/Fender Removal/Installation
    169
  - Sportsman Rear Cab / Fender Removal / Installation
    170
  - X2 Rear Quarter Panel Removal / Installation
    170
  - Sportsman Rear Storage Removal / Installation
    171
  - Radiator Screen Removal
    171
  - Sportsman Body Assembly Exploded View
    172
  - X2 Body Assembly Exploded View
    173
  - Body Rack Exploded Views
    174
  - Headlight Pod Exploded View
    175
- Steering
  176
  - Handlebar Block Installation Procedure
    176
  - Steering / A-Arm Exploded View
    177
  - A-Arm Replacement
    178
  - Ball Joint Replacement
    179
  - Steering Post Removal
    180
  - Steering Post Assembly
    180
- Suspension
  180
  - Front Strut Cartridge Replacement
    180
  - Strut Assembly
    181
  - Sportsman Rear Suspension Assembly
    182
  - X2 Rear Suspension Exploded View
    183
  - X2 Torsion Bar Exploded View
    184
- X2 Cargo Box
  185
  - Exploded View
    185
  - Removal / Installation
    186
- X2 Seat Assembly
  188
Clutch System Chapter 6 Clutch System

191
- Chapter 6
  192
- Component Fastener Torques
  192
- Special Tools
  192
- Special Tools and Specifications
  192
- Pvt Exploded Views
  193
- Pvt System
  196
  - Pvt Operation Overview
    196
  - Drive Clutch Operation
    196
  - Driven Clutch Operation
    196
  - Ebs Clutch Operation
    197
  - Pvt Maintenance / Inspection
    197
  - Drive Clutch Spring
    198
  - Optional Shift Weights
    199
  - Pvt Drying
    200
  - Pvt Disassembly
    200
  - Pvt Installation
    201
  - Drive Belt Removal / Inspection
    202
  - Drive Belt Installation
    203
  - Clutch Alignment
    204
  - Clutch Offset
    204
- Ebs Drive Clutch Service
  205
  - Drive Clutch Disassembly
    205
  - Spider Removal
    205
  - Button to Tower Clearance Inspection
    207
  - Shift Weight Inspection
    207
  - Drive Clutch Inspection
    207
  - Moveable Sheave Bushing Inspection
    208
  - Drive Clutch Bushing Service
    208
  - One-Way Clutch Inspection (Drive Clutch)
    210
  - Drive Clutch Reassembly
    210
- Ebs Driven Clutch Service
  212
- Standard Drive Clutch
  218
  - Drive Clutch Disassembly
    218
  - Spider Removal
    219
  - Button to Tower Clearance Inspection
    220
  - Shift Weight Inspection
    220
  - Drive Clutch Reassembly
    222
- Standard Driven Clutch
  224
  - Disassembly
    224
  - Inspection
    224
  - Assembly
    225
- Pvt Troubleshooting
  226
  - Overheating
    226
  - Problem, Cause and Remedy Chart
    227
Final Drive Chapter 7 Final Drive

229
- Chapter 7
  230
- Final Drive
  230
- Front Drive Axle
  230
  - Removal
    230
  - Installation
    232
- Gearcase Fluid / Capacity
  230
- Special Tools
  230
- Specifications
  230
- Torque Table
  230
- Front Drive Shaft (CV) Boot
  232
  - Inspection
    232
  - Replacement
    232
- Front Hub
  234
  - Disassembly
    234
  - Assembly
    234
- Prop Shaft - Front or Rear
  235
  - Removal and Installation
    235
- U-Joint
  235
  - Disassembly
    235
  - Assembly
    236
- Drive Axle Exploded Views
  238
  - Drive Shafts and Propshafts
    238
- Front Gearcase - Centralized Hilliard (Standard Models)
  239
  - Exploded View (Standard Models)
    239
  - Operation
    240
  - Gearcase Removal
    240
  - Disassembly / Inspection
    241
  - Reassembly / Inspection
    245
  - Setting Ring Gear Backlash
    246
  - Front Gearcase Diagnosis
    247
  - Gearcase Installation
    248
- Front Gearcase - Active Descent Control (Deluxe Models)
  249
  - Adc Gearcase Exploded View (Deluxe Models)
    249
  - Operation
    250
  - Adc Coil Testing
    251
  - Adc Differential Hydraulic Circuit Bleeding
    251
  - Disassembly / Inspection
    251
  - Adc Gearcase Piston Replacement Procedure
    255
  - Assembly
    257
- Rear Hub
  260
  - Removal
    260
  - Disassembly
    261
  - Assembly
    262
  - Installation
    262
- Rear Drive (CV) Shaft
  263
  - Removal
    263
  - Service
    264
  - CV Boot Replacement
    265
  - Installation
    266
  - Drive Shaft and CV Joint Handling Tips
    267
General Information Chapter 8 General Information

269
- Chapter 8
  270
- General Information
  270
- Mounting Exploded View
  270
- Transmission - General
  270
- Gear Selector Removal
  271
- Lubrication
  271
- Special Tools
  271
- Torque Specifications
  271
- Transmission Removal
  271
- Transmission Installation
  273
- Troubleshooting Checklist
  274
- Transmission Service
  275
  - Exploded View
    275
  - Transmission Disassembly
    277
  - Transmission Assembly
    282
Brakes Chapter 9 Brakes

289
- Chapter 9
  290
- Component Service Limits
  290
- Specifications
  290
- Torque Table
  290
- Brake System Exploded Views
  291
  - X2 System Component Exploded View
    291
  - Sportsman System Component Exploded View
    292
- Brake Caliper Exploded Views
  293
- Hydraulic Brake System
  294
  - Operation Overview
    294
  - Brake Noise Troubleshooting
    295
  - Brake Bleeding / Fluid Change
    295
- Front Master Cylinder
  297
  - Removal
    297
  - Installation
    297
- Front Brakes
  298
  - Pad Removal
    298
  - Assembly
    299
  - Brake Burnishing Procedure
    300
- Front Brake Disc
  300
  - Inspection
    300
  - Removal / Replacement
    301
- Front Caliper
  302
  - Removal
    302
  - Inspection
    303
  - Reassembly
    303
  - Installation
    304
- Rear Brake Pad
  305
  - X2 Pad Removal
    305
  - X2 Pad Installation
    306
  - Sportsman Rear Pad Removal
    307
  - Sportsman Rear Pad Installation
    308
  - Brake Burnishing Procedure
    308
- X2 Rear Caliper
  309
  - Removal
    309
  - Inspection
    310
  - Reassembly
    310
- Sportsman Rear Caliper
  311
  - Removal and Inspection
    311
  - Assembly
    312
- Rear Brake Disc
  313
  - Inspection
    313
- Rear Master Cylinder
  314
  - X2 Exploded View
    314
  - Overview
    315
  - X2 Rear Master Cylinder Removal and Installation
    315
  - Sportsman Rear Master Cylinder Removal / Installation
    316
  - Pedal Removal and Installation
    317
- Troubleshooting
  317
  - Brakes Squeal
    317
  - Poor Brake Performance
    317
  - Lever Vibration
    317
  - Caliper Overheats (Brakes Drag)
    317
  - Brakes Lock
    317
Chapter 10 Electrical

319
- General Information
  321
- Ignition System / Basic Electrical Components
  321
- Special Tools
  321
- Electrical Service Notes
  322
- Troubleshooting
  322
- Power Distribution Modules (Pdm)
  323
  - Sportsman Efi Overview
    323
  - Sportsman 450 Overview
    328
- Instrument Cluster
  331
  - Overview
    331
  - Instrument Cluster Diagnostic Mode
    332
  - Setting a New Service Interval
    334
  - Efi Diagnostic Mode
    335
  - Speedometer Removal
    336
  - Speedometer Installation
    336
- All Wheel Drive and Speedometer Troubleshooting
  337
- Active Descent Control (Adc) Coil
  342
  - Operation Overview
    342
  - Diagnosing System Failures
    342
- All Wheel Drive (Awd) Coil
  342
- Cooling System Components
  343
  - Fan Control Circuit Operation
    343
  - Fan Control Bypass Test
    343
  - Fan Motor Current Draw Test
    343
  - Coolant Temperature Sensor
    344
- Gear Position Indicator Switch
  344
  - Test Diagram
    344
- Electronic Throttle Control (Etc) Switch
  345
  - Operation Overview
    345
  - Etc Test
    345
- Ignition System
  346
- Charging System
  350
  - Current Draw - Key off
    350
  - Break Even Test
    350
  - Alternator Output Test
    350
  - Charging System Testing Diagrams
    352
- Differential Solenoid
  354
  - Testing
    354
  - Replacement
    354
- Lighting
  354
  - High Beam Headlight Bulb Replacement
    354
  - Headlight Housing Relacement
    355
  - High Beam Headlight Adjustment
    356
  - Lower Headlamp Removal / Installation
    356
  - Low Beam Headlight Adjustment
    357
  - Headlamp Switch Test
    357
  - Work Light Switch
    358
  - Brake Light / Work Light Replacement
    358
  - Brake Light Switch Test
    359
- Fuel Sender
  360
- Speed Sensor
  360
  - Testing
    360
  - Replacement
    360
- Accessory Power
  361
  - Wire Connections
    361
- Starter System
  362
  - Troubleshooting
    362
  - Voltage Drop Test
    362
  - Starter Lockout Troubleshooting- Sportsman
    362
  - Starter Lockout Troubleshooting- Efi Models
    362
  - Starter Lockout Diagram- Efi
    363
  - Starter Motor Removal / Disassembly
    364
  - Brush Inspection / Replacement
    364
  - Armature Testing
    365
  - Starter Solenoid Bench Test
    366
  - Starter Exploded View
    366
- Starter Drive
  367
  - Pinion Gear - Anti-Kick out Shoe, Garter Spring Replacement
    367
- Starter System Testing Flow Chart
  368
- Basic Winch Wiring
  369
  - Pre-Wired Models
    369
- Troubleshooting Diagrams
  370
  - Power on - Efi
    370
  - Start Circuit - Efi
    370
  - Ignition Coil - Efi
    371
  - Fuel Pump - Efi
    371
  - Fan - Efi
    372
  - Charging System - Efi
    372
  - All Wheel Drive - Efi
    373
  - Transmission Switch - Efi
    373
  - Reverse Override - Efi
    374
  - Differential Solenoid - X2
    374
- Battery
  375
  - Battery Identification
    375
  - Battery Activation
    375
  - Terminal Preparation
    376
  - Battery Removal
    376
  - Battery Installation
    376
  - Off Season Storage
    377
  - Low Maintenance Battery Off-Season Storage
    377
  - Battery Testing
    377
  - Conventional Battery Ocv - Open Circuit Voltage Test
    377
  - Conventional Battery Specific Gravity Test
    377
  - Battery Load Test
    378
  - Charging Procedure
    378
  - Low Maintenance Battery Check
    379
  - Low Maintenance Battery Charging
    379
  - Low Maintenance Battery - Ocv- Open Circuit Voltage Test
    380
  - Low Maintenance Battery Load Test
    380
  - Low Maintenance Battery Charging Procedure
    380
- International
  381
- 500 Efi International / Quadricycle Brake System
  382
  - Exploded View
    383
- 500 Efi International / Quadricycle Steering Post and Lock
  384
  - Steering Assembly Exploded View
    384
- 500 Efi Quadricycle Emissions System
  385
  - Overview
    385
- Quadricycle Electrical
  386
  - Turn / Hazard Signal Diagram
    386

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