Polaris 2007 SPORTSMAN X2 800 EFI - User Manual

2007 SPORTSMAN 700/800/800 X2 EFI
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service
procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as
specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
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. 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.

Polaris 2007 SPORTSMAN X2 800 EFI Specifications

General

Brand	Polaris
Model	2007 SPORTSMAN X2 800 EFI
Category	Offroad Vehicle
Language	English

Summary

Maintenance

Periodic Maintenance Chart

Schedule of required maintenance intervals for the vehicle.

Engine

Engine Disassembly and Inspection

Procedures for disassembling and inspecting engine components.

Engine Reassembly

Step-by-step instructions for engine reassembly.

Fuel Injection

Electronic Fuel Injection

Overview of EFI principal components and operation.

Fuel Pump

Fuel pump operation, testing, and replacement procedures.

Fuel Injectors

Fuel injector operation, service, and replacement.

Crankshaft Position Sensor (CPS)

CPS operation, testing, and replacement.

Temperature; Barometric Air Pressure Sensor (T-BAP)

T-BAP sensor operation, testing, and replacement.

Throttle Position Sensor (TPS)

TPS operation, replacement, and initialization.

Engine Temperature Sensor

Engine temperature sensor operation, testing, and replacement.

Body; Steering; Suspension

Body

Procedures for removal and installation of various body panels and components.

Steering

Procedures for steering system components, including handlebar and A-arm.

Suspension

Procedures for front and rear suspension components and assemblies.

Clutch System

PVT System

Overview of PVT system operation and maintenance.

EBS Drive Clutch Service

Service procedures for the EBS drive clutch.

EBS Driven Clutch Service

Service procedures for the EBS driven clutch.

Standard Drive Clutch

Standard Driven Clutch

PVT Troubleshooting

Final Drive

Front Drive Axle

Front Drive Shaft (CV) Boot

Front Gearcase - Centralized Hilliard (Standard Models)

Exploded view, operation, and service for the front gearcase.

Front Gearcase - Active Descent Control (Deluxe Models)

Operation, testing, and service for the ADC front gearcase.

Rear Drive (CV) Shaft

Rear Gearcase

Rear gearcase removal, disassembly, inspection, and reassembly.

Transmission

Sportsman Transmission

Transmission Service

Procedures for transmission removal, disassembly, assembly, and installation.

Brakes

Hydraulic Brake System

Front Brakes

Rear Brake Pad

X2 Rear Caliper

Sportsman Rear Caliper

Rear Brake Disc

Rear Master Cylinder

Troubleshooting

Troubleshooting common brake system issues like noise and performance.

Electrical

Speedometer Troubleshooting

Active Descent Control (ADC) Coil

All Wheel Drive (AWD) Coil

Electronic Throttle Control (ETC) Switch

Ignition System

Flywheel identification, ignition system overview, and troubleshooting.

Charging System

Charging system tests, including current draw and alternator output.

800 EFI International

800 EFI International Brake System

Overview of the international brake system.

800 EFI International Steering Post and Lock Assembly

800 EFI International Electrical