2007 Polaris Sportsman 700 800 EFI Service Manual
User Manual: 2007 Polaris Sportsman 700 800 800 EFI Service Manual
Open the PDF directly: View PDF
Page Count: 393 [warning: Documents this large are best viewed by clicking the View PDF Link!]
- FOREWORD
- CHAPTER INDEX
- CH 1 - GENERAL INFORMATION
- MODEL INFORMATION
- Model Number/VIN Identification
- Model Number
- Engine Designation Numbers
- VIN Identification
- TRANSMISSION I.D. LOCATION
- Engine and Machine Serial Numbers
- PUBLICATIONS
- Publication Numbers
- PAINT CODES
- Paint Codes
- REPLACEMENT KEYS
- Keys, Replacement
- Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison
- Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison
- 2007 SPORTSMAN 700 EFI
- Specifications, Sportsman 700 EFI
- 2007 SPORTSMAN 800 EFI
- Specifications, Sportsman 800 EFI
- 2007 SPORTSMAN X2 800 EFI
- Specifications, Sportsman 800 X2 EFI
- Misc. Tables
- MISC. NUMBERS/CHARTS
- CH 2 - MAINTENANCE
- MAINTENANCE
- Maintenance Chart, Periodic
- LUBRICATION / FLUIDS
- SPORTSMAN Component Locations
- Component Locations, Sportsman
- SPORTSMAN X2 Component Locations
- Component Locations
- Polaris Lubricants, Maintenance and Service Products
- Lubricants/Fluids, Polaris Brand Part Numbers
- Polaris Lubricant Symbol Identification
- Lubricants/Fluids, Polaris Brand Symbol Identification Chart
- Pre-Ride / Daily Inspection
- Pre-ride Checklist
- Lubrication / Grease Points
- Lubrication / Grease Points
- Front Gearcase Lubrication
- Front Gearcase Lubrication
- Transmission Lubrication
- ADC Differential Hydraulic Circuit Fluid Change
- Gearcase, ADC Hydraulic Fluid Change
- VEHICLE INSPECTION
- Shift Link Rod Inspection
- Shift Linkage Inspection
- Throttle Inspection
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
- Throttle Cable
- Fuel System
- Fuel Filter
- Vent Lines
- Vent Lines
- Compression Test
- Compression Test
- Engine Mounts
- Engine Mount
- Spark Plug
- Spark Plug
- Active Descent Control (ADC) Reservoir Level
- ADC reservoir level inspection
- Battery Maintenance
- Battery Maintenance
- Cooling System
- Cooling System
- Coolant Strength / Type
- Cooling Hoses
- Cooling System Hoses
- Radiator
- Radiator
- Cooling System Pressure Test
- Cooling System - Pressure Test
- Reservoir Level Inspection
- Cooling System - Coolant Level
- Radiator Coolant Level
- Cooling System - Radiator Level
- Air Filter Service
- Air Filter Service
- Air Box Sediment Tube
- Air Box Sediment Tube
- Engine Breather
- Engine Breather Hoses
- PVT Inspection / Drying Procedure
- PVT Drying
- Engine Ground
- Engine Ground
- Engine Oil Level
- Engine Oil Level
- Oil/filter Change
- Engine Oil and Filter Change
- Steering Inspection
- Steering
- Tie Rod / Steering
- Tie Rod / Steering Inspection
- Camber/Caster
- Camber / Caster
- Wheel Alignment
- Wheel Alignment
- Toe Alignment
- Exhaust Pipe
- Exhaust Pipe
- Brake System Inspection
- Brake System Inspection
- Brake Pads
- Brake Pad Inspection
- Brake Hose Inspection
- Brake Hose Fitting Inspection
- Auxiliary (Rear) Brake Test
- Auxiliary (Rear) Brake Test
- Auxiliary Brake Adjustment
- Auxiliary Brake Adjustment
- Suspension: Spring Preload Adjustment
- Suspension Adjustment
- Front Suspension
- Suspension, Front
- Rear Suspension
- Suspension, Rear
- CV Shaft Boot Inspection
- CV Shaft Boot Inspection
- ATV Controls
- Wheel Inspection
- Wheel Removal: Front Or Rear
- Wheel Removal
- Wheel Installation
- Wheel Installation
- Tire Pressure
- Tire Inspection
- Tire Inspection
- Frame, Nuts, Bolts, Fasteners
- Frame, Nuts, Bolts Fastener Inspection
- Front / Rear Storage Compartments
- Storage Compartments, Front & Rear
- Winch Operation (If Equipped)
- Warn Winch Operation
- Cleaning And Storage Of ATV
- Cleaning and Storage of ATV
- Exhaust, 800 EFI
- Maintenance Schedule
- Maintenance Schedule
- CH 3 - ENGINE
- SPECIFICATIONS
- Crankcase Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Exploded Views
- Engine Fastener Torque Patterns
- Engine Fastener Torques
- Torque Specifications
- Engine Torque Table
- Torque Specs - Engine
- 700/800 EFI Engine Service Specifications
- Engine Service Specifications
- Special Tools
- Special Tools, Engine
- GENERAL ENGINE SERVICE
- Accessible Components
- Engine, Accessible Components
- Piston Identification
- Engine Piston Identification
- Cooling System Specifications
- Cooling System Specifications
- Specifications, Cooling System
- Engine Cooling System
- Cooling System Pressure Test
- Cooling System, Pressure Test
- Engine Cooling System
- Four Stroke - Coolant Air Bleeding Procedure
- Cooling System Bleeding Procedure
- Engine Removal (Typical)
- Engine Removal / Install Procedure
- Engine Installation Notes
- Engine Installation Notes
- Cylinder Hone Selection And Honing Procedure
- Engine Cylinder Honing
- Honing To Deglaze
- Cylinder Honing To De-glaze
- Cleaning the Cylinder After Honing
- Oil Flow Chart
- Engine Oil Flow Chart
- Engine Lubrication Specifications
- Specifications, Engine Lubrication
- Engine Lubrication
- OIL PRESSURE TEST
- Engine Oil Pressure Test
- ENGINE DISASSEMBLY AND INSPECTION
- Cylinder Head Assembly Exploded View
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Engine Rocker Arm Inspection
- Push Rods
- Engine Pushrod Inspection
- Cylinder Head Removal
- Engine Cylinder Head Removal
- Cylinder Head Inspection
- Engine Cylinder Head Inspection
- Cylinder Head Warp
- Engine Cylinder Head Warp
- Valve Seal/Spring Service (On Engine)
- Valve Seal/Spring Service
- Engine Valve Seal/Spring Service
- Cylinder Head Disassembly
- Cylinder Head Disassembly
- Valve Inspection
- Engine Valve Inspection
- Combustion Chamber
- Combustion Chamber
- Valve Seat Reconditioning
- Valve Seat Reconditioning
- Engine Valve Seat Reconditioning
- Cylinder Head Reassembly
- Engine Cylinder Head Assembly
- Cylinder Head Assembly
- Valve Sealing Test
- Engine Valve Sealing Test
- Valve Sealing Test
- Cylinder Removal
- Engine Cylinder Removal
- Valve Lifter Removal/Inspection
- Engine Valve Lifter Removal, Inspection
- Piston Removal
- Engine Piston Removal, Inspection
- Cylinder Inspection
- Engine Cylinder Inspection
- Cylinder Inspection
- Piston-To-Cylinder Clearance
- Piston to Cylinder Clearance
- Engine Piston to Cylinder Clearance
- Piston/rod Inspection
- Engine Piston to Rod Clearance
- Piston to Rod Inspection
- Piston Ring Installed Gap
- Piston Ring Installed Gap
- Engine Piston Ring Installed Gap
- Starter Drive/Bendix Removal Inspection
- Starter Drive Removal
- Engine Starter Drive Removal
- Flywheel / Stator Removal / Inspection
- Stator, Removal
- Flywheel, Removal
- Flywheel / Stator Removal
- Engine Flywheel / Stator Removal
- Engine Crankcase Disassembly / Inspection
- Engine Flywheel Removal
- Engine Starter Removal
- Engine Gear(s) Removal
- Specification, Timing Gear Alignment
- Timing Gear Mark Alignment
- Cam Gear, Removal
- Cam Gear, Reassembly
- Special Tool, Cam Gear Installation Kit
- Balance Shaft Gear, Removal
- Crankshaft Gear, Removal
- Engine Crankshaft Gear Removal
- Oil Pump, Removal
- Engine Oil Pump Removal
- Oil Pump, Disassembly
- Specification, Oil Pump Rotor Clearance
- Oil Pump, Reassembly
- Engine Balance Shaft Removal
- Camshaft Inspection
- Engine Camshaft Inspection
- ENGINE REASSEMBLY
- CRANKCASE REASSEMBLY
- Engine Crankcase Assembly
- Specifications, Oil Baffle Bolt Torque
- Specifications, Oil Pick-up Bolt Torque
- Engine Camshaft Installation
- Engine Crankshaft Installation
- Specifications, Crankcase Fastener Torque
- Engine Cylinder Installation
- Engine Piston Installation
- Specification, Cam Thrust Plate Fastener Torque
- Engine Oil Pump Installation
- Specification, Oil Pump Bolt Torque
- Engine Gears, Installation
- Specification, Balance Shaft Gear Bolt Torque
- Specification, Camshaft Gear Bolt Torque
- Gear / Stator Housing Seal Replacement
- Engine Stator Gear Cover Seal(s) Installation
- Engine Stator Installation
- Engine Oil Priming
- Flywheel / Stator Installation
- Engine Flywheel / Stator Installation
- Cylinder Head Reassembly
- Engine Head Assembly
- TROUBLESHOOTING
- 800 EFI Exhaust System (DELUXE)
- SPECIFICATIONS
- CH 4 - FUEL INJECTION
- GENERAL INFORMATION
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- FUEL FILTERS
- FUEL INJECTORS
- CRANKSHAFT POSITION SENSOR (CPS)
- TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE TEMPERATURE SENSOR
- TROUBLESHOOTING
- Diagnostics Using “Blink Codes”
- Engine Diagnostic Codes
- EFI Troubleshooting
- EFI Troubleshooting
- EFI CIRCUIT - Power On
- Fuel System, EFI Circuit Diagrams
- Troubleshooting, EFI Circuit Diagrams
- EFI CIRCUIT - Crank Position Sensor
- EFI CIRCUIT - Fuel Pump
- EFI CIRCUIT - Throttle Position Sensor
- EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor
- EFI CIRCUIT - Engine Temperature
- EFI CIRCUIT - Malfunction Indicator Light
- CH 5 - BODY/STEERING/SUSPENSION
- GENERAL INFORMATION
- BODY
- Side Panel Removal
- Side Panel Removal
- Front Cover Removal / Installation
- Front Cover Removal / Installation
- Foot Well Removal / Installation
- Foot Well Removal / Installation
- X2 Foot Well Removal / Installation
- Foot Well Removal / Installation
- Front Storage Removal
- Front Storage Removal
- Front Storage Installation
- Front Storage Installation
- Sportsman Rear Rack Removal / Installation
- Rear Rack Removal / Installation
- Front Cab/Fender Removal/Installation
- Front Cab Removal / Installation
- Sportsman Rear Cab / Fender Removal / Installation
- Rear Cab Removal / Installation
- X2 Rear Quarter Panel Removal / Installation
- Sportsman Rear Storage Removal / Installation
- Rear Storage Removal / Installation
- Radiator Screen Removal
- Radiator Screen Removal
- Sportsman Body Assembly Exploded View
- Body Assembly Exploded View
- X2 Body Assembly Exploded View
- Body Assembly Exploded View
- Body / Rack Exploded Views
- Body Rack Exploded View
- Headlight Pod Exploded View
- Headlight Pod Exploded View
- STEERING
- SUSPENSION
- X2 CARGO BOX
- X2 SEAT assembly
- CH 6 - CLUTCH SYSTEM
- SPECIAL TOOLS AND SPECIFICATIONS
- PVT EXPLODED VIEWS
- PVT SYSTEM
- PVT Operation Overview
- PVT Operation
- Drive Clutch Operation
- PVT Drive Clutch Operation
- Drive Clutch, Operation
- Driven Clutch Operation
- PVT Driven Clutch Operation
- Driven Clutch, Operation
- EBS Clutch Operation
- PVT, EBS Clutch Operation
- EBS, Driven Clutch Operation
- PVT Maintenance / Inspection
- PVT Maintenance / Inspection
- Drive Clutch Spring
- PVT Drive Clutch Specifications
- Drive Clutch Springs
- Optional Shift Weights
- PVT Drive Clutch Shift Weights
- Drive Clutch Weights
- PVT Drying
- PVT Drying
- PVT Disassembly
- PVT Disassembly
- PVT Installation
- PVT Assembly
- Drive Belt Removal / Inspection
- PVT, Drive Belt Removal/Inspection
- Drive Belt, Removal/Inspection
- DRIVE BELT INSTALLATION
- PVT, Drive Belt Installation
- Drive Belt, Installation
- Clutch Alignment
- PVT, Clutch Alignment
- Clutch Alignment
- Clutch Offset
- PVT, Clutch Offset
- Clutch Offset
- EBS DRIVE CLUTCH SERVICE
- EBS Drive Clutch Service
- Drive Clutch Disassembly
- PVT, Drive Clutch Disassembly
- Spider Removal
- PVT, Drive Clutch Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- PVT, Button to Tower Clearance
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- PVT, Moveable Sheave Inspection
- Drive Clutch Bushing Service
- PVT, EBS Drive Clutch Bushing Service
- PVT, EBS Drive Clutch Cover Bushing Remove/Install
- One-Way Clutch Inspection (Drive Clutch)
- Drive Clutch Reassembly
- PVT, Drive Clutch Reassembly
- EBS DRIVEN CLUTCH SERVICE
- EBS Driven Clutch Service
- standard drive clutch
- Drive Clutch, Standard Service
- Drive Clutch Disassembly
- PVT, Drive Clutch Disassembly
- Spider Removal
- PVT, Drive Clutch Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- PVT, Button to Tower Clearance
- Sheave / Bushing Inspection
- PVT, Moveable Sheave Inspection
- Drive Clutch Bushing Service
- PVT, EBS Drive Clutch Bushing Service
- PVT, EBS Drive Clutch Cover Bushing Remove/Install
- Drive Clutch Reassembly
- PVT, Drive Clutch Reassembly
- standard driven clutch
- Driven Clutch, Standard Service
- PVT TROUBLESHOOTING
- Clutch, Troubleshooting
- CH 7 - FINAL DRIVE
- SPECIFICATIONS
- FRONT DRIVE AXLE
- FRONT DRIVE SHAFT (CV) BOOT
- FRONT HUB
- PROP SHAFT - FRONT OR REAR
- U-JOINT
- U-joint, Disassembly and Assembly
- DRIVE AXLE EXPLODED VIEWS
- FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MoDELS)
- Front Gearcase, Operation
- Exploded View (Standard Models)
- Front Gearcase, Exploded View
- Operation
- Gearcase Removal
- Front Gearcase, Removal
- Disassembly / Inspection
- Front Gearcase, Disassembly / Inspection
- Reassembly / Inspection
- Front Gearcase, Reassembly / Inspection
- Setting Ring Gear Backlash
- Front Gearcase Diagnosis
- Front Gearcase, Diagnoses
- Gearcase Installation
- Front Gearcase, Installation
- FRONT GEARCASE - Active descent control (deluxe models)
- ADC Gearcase Exploded View (Deluxe Models)
- Front Gearcase, Active Descent Control Exploded View
- Operation
- Active Descent Control Gearcase
- ADC Coil Testing
- ADC Differential Hydraulic Circuit Bleeding
- Disassembly / Inspection
- ADC Gearcase, Disassembly / Inspection
- ADC Gearcase Piston Replacement Procedure
- ADC Gearcase Piston Service
- Assembly
- Front Gearcase, Reassembly
- REAR HUB
- REAR DRIVE (CV) SHAFT
- REAR GEARCASE
- sPORTSMAN 8.3-8.18
- sPORTSMAN X2 8.19-8.38
- CH 8 - TRANSMISSION / SPORTSMAN
- CH 8 - TRANSMISSION / X2
- Transmission
- TRANSMISSION EXPLODED VIEWS
- sPECIFICATIONS
- TRANSMISSION SERVICE
- Gear Selector Removal
- Transmission Removal
- Transmission, Removal
- Transmission Installation
- Transmission, Install
- Troubleshooting Checklist
- Transmission Disassembly
- Transmission, Disassembly
- Transmission assembly
- Transmission, Reassembly
- Transmission front output shaft backlash procedure
- Transmission, Output Shaft Backlash Procedure
- Transmission
- CH 9 - BRAKES
- SPECIFICATIONS
- BRAKE SYSTEM Exploded Views
- Brake System Exploded Views
- BRAKE CALIPER EXPLODED VIEWS
- Brake Caliper Exploded View
- HYDRAULIC BRAKE SYSTEM
- Hydraulic Brake System Operation Overview
- FRONT MASTER CYLINDER
- Brake, Master Cylinder Removal
- FRONT BRAKES
- Brake Pad, Removal and Installation
- FRONT BRAKE DISC
- Brake Disc, Front
- FRONT CALIPER
- Brake Caliper, Front
- REAR BRAKE PAD
- Brake Pad, Rear
- X2 REAR CALIPER
- Brake Caliper Removal, Rear
- Sportsman REAR CALIPER
- REAR BRAKE DISC
- Brake Disc, Inspection
- REAR MASTER CYLINDER
- Brake, Rear Auxiliary Master Cylinder
- TROUBLESHOOTING
- Brakes, Troubleshooting
- CH 10 - ELECTRICAL
- INSTRUMENT CLUSTER
- Instrument Cluster (Speedometer) Overview
- Overview
- Speedometer, Funtions Overview
- Instrument Cluster Diagnostic Mode
- Diagnostic Mode, Instrument Cluster
- Clock, Setting Time of Day
- Setting A New Service Interval
- Instrument Cluster, Setting New Service Interval
- Service Intervals, Speedometer
- EFI Diagnostic Mode
- EFI Diagnostic Mode Using Instrument Cluster
- Diagnostic Mode, EFI System
- Diagnostic Codes
- Speedometer Removal
- Speedometer Removal
- Speedometer Installation
- Speedometer Installation
- SPEEDOMETER TROUBLESHOOTING
- ACTIVE DESCENT CONTROL (ADC) COIL
- Active Descent Control (ADC) Coil
- ALL WHEEL DRIVE (AWD) COIL
- All Wheel Drive (AWD) Coil
- COOLING SYSTEM COMPONENTS
- GEAR POSITION INDICATOR SWITCH
- ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- IGNITION SYSTEM
- CHARGING SYSTEM
- RELAYS
- FUSES/Circuit Breaker
- LIGHTING
- High Beam Headlight Bulb Replacement
- High Beam Bulb Replacement
- Headlight Housing Replacement
- Headlight Housing Replacement
- High Beam Headlight Adjustment
- High Beam Headlight Adjustment
- Lower Headlamp Removal / Installation
- Lower Headlamp Removal
- Low Beam Headlight Adjustment
- Low Beam Headlight Adjustment
- Headlamp Switch Test
- Headlamp Switch Test
- Sportsman Work Light Switch (Deluxe)
- Work Light Switch
- Sportsman Brake Light / Work Light (Deluxe) Replacement
- Brake Light / Work Light Switch Replacement
- X2 BRAKE LIGHT / WORK LIGHT (Deluxe) REPLACEMENT
- Brake Light / Work Light Switch Replacement
- Brake Light Switch
- Brake Light Switch
- FUEL SENDER
- X2 DIFFERENTIAL System
- X2 SPEED SENSOR
- ACCESSORY POWER
- STARTER SYSTEM
- 700/800 Starter Lockout Overview and Diagnostic
- Starter Interlock
- Interlock, Starter, 700/800 EFI
- 800 X2 Starter Lockout Overview and Diagnostic
- Starter Interlock
- Interlock, Starter, 800 X2 EFI
- Troubleshooting
- Starter System, Troubleshooting
- Voltage Drop Test
- Voltage Drop Test
- Starter Motor Removal / Disassembly
- Starter Motor, Removal
- BRUSH INSPECTION / REPLACEMENT
- Starter Brush Inspection / Replacement
- Armature Testing
- Starter Armature Testing
- Starter Reassembly / Installation
- Starter Reassembly / Installation
- Starter Solenoid Bench Test
- Starter Drive
- Starter Drive
- Starter Exploded View
- Starter Assembly Exploded View
- STARTER SYSTEM TESTING FLOW CHART
- BASIC WINCH WIRING- PRE-WIRED MODELS
- BATTERY
- Battery Identification
- Battery Activation (Conventional)
- Battery Activation, Conventional
- Battery Terminals/Bolts
- Battery Terminals/Bolts
- Conventional Battery Inspection / Removal
- Battery Removal / Inspection, Conventional
- Conventional Battery Installation
- Conventional Battery Testing
- Conventional Battery OCV - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Specific Gravity Test, Conventional Battery
- Battery Load Test
- Battery Load Test
- Off Season Storage
- Battery Off Season Storage
- Charging Procedure
- Charging Procedure
- Low Maintenance Battery
- Low Maintenance Battery Info
- Low Maintenance Battery Charging
- Low Maintenance Battery Charging
- Low Maintenance Battery Inspection / Removal
- Battery Inspection / Removal, Low Maintenance
- Low Maintenance Battery Installation
- Battery Installation, Low Maintenance
- Low Maintenance Battery - OCV- Open Circuit Voltage Test
- Battery Open Circuit Voltage (OCV), Low Maintenance
- Low Maintenance Battery Load Test
- Battery Load Test, Low Maintenance
- Low Maintenance Battery Off-season Storage
- Battery Off Season Storage, Low Maintenance
- Low Maintenance Battery Charging Procedure
- Battery Charging Procedure, Low Maintenance
- CH 11 - INTERNATIONAL
- INDEX
- WIRE DIAGRAMS