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2007 SPORTSMAN X2 800
Polaris 2007 SPORTSMAN X2 800 User Manual
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8.20
Sportsman X2 Transmission
TRANSMISSION EXPLODED VIEWS
X2 T
ransmission
Exploded View
262
242
= THREAD LOCKING AGENT FOR ALL ‘FT. LBS.’ FASTENERS
= THREAD LOCKING AGENT FOR ‘INCH LBS. ‘ FASTENERS
271
273
Table of Contents
General Information Chapter 1 1
5
Table of Contents
5
Chapter 1
6
Engine and Machine Serial Numbers
6
General
6
General Information
7
Engine Designation Numbers
6
Model Information
6
Model Number
6
Transmission I.D. Location
6
Vin Identification
6
Sportsman 'Deluxe' and 'Standard' Model Component Comparison
8
2007 Sportsman 700 Efi
10
Fuel System
11
2007 Sportsman 800 Efi
12
2007 Sportsman X2 800 Efi
14
Misc. Numbers/Charts
16
Standard Torque Specifications
16
Special Tools
16
Sae Tap Drill Sizes
17
Metric Tap Drill Sizes
17
Conversion Table
18
Glossary of Terms
19
Maintenance Chapter 2 Maintenance 2
21
Chapter 2
23
Maintenance
23
Maintenance Chart Key
23
Overview
23
Periodic Maintenance Chart
24
Lubrication / Fluids
27
Polaris Lubricants, Maintenance and Service Products
29
Polaris Lubricant Symbol Identification
30
Pre-Ride / Daily Inspection
30
Lubrication / Grease Points
31
Front Gearcase Lubrication
32
Transmission Lubrication
33
Adc Differential Hydraulic Circuit Fluid Change
34
Vehicle Inspection
34
Throttle Inspection
35
Throttle Cable / Electronic Throttle Control Adjustment
35
Fuel System
36
Vent Lines
36
Compression Test
36
Engine Mounts
37
Spark Plug
37
Active Descent Control (Adc) Reservior Level
37
Battery Maintenance
38
Cooling System
38
Coolant Strength / Type
39
Cooling Hoses
39
Radiator
39
Cooling System Pressure Test
39
Reservoir Level Inspection
39
Radiator Coolant Level
40
Air Filter Service
40
Air Box Sediment Tube
41
Engine Breather
41
Pvt Inspection / Drying Procedure
42
Engine Ground
42
Engine Oil Level
42
Oil/Filter Change
43
Final Drive
44
Steering Inspection
44
Tie Rod / Steering
44
Camber/Caster
44
Wheel Alignment
45
Toe Alignment
45
Exhaust Pipe
46
Brake System Inspection
46
Brake Pads
47
Brake Hose Inspection
47
Auxiliary (Rear) Brake Test
47
Auxiliary Brake Adjustment
48
Suspension: Spring Preload Adjustment
48
Front Suspension
48
Rear Suspension
48
CV Shaft Boot Inspection
48
Atv Controls
49
Wheel Installation
49
Wheel Inspection
49
Wheel Removal: Front or Rear
49
Frame, Nuts, Bolts, Fasteners
50
Front / Rear Storage Compartments
50
Tire Inspection
50
Tire Pressure
50
Cleaning and Storage of Atv
53
Chapter 3 Engine
57
Crankcase Exploded Views
58
Specifications
58
Engine Fastener Torque Patterns
65
Torque Specifications
66
700/800 Efi Engine Service Specifications
67
Special Tools
69
General Engine Service
70
Accessible Components
70
Piston Identification
70
Cooling System Specifications
70
Cooling System Pressure Test
71
Four Stroke - Coolant Air Bleeding Procedure
71
Engine Removal (Typical)
72
Engine Installation Notes
74
Cylinder Hone Selection and Honing Procedure
74
Electrical
75
Honing to Deglaze
75
Cleaning the Cylinder after Honing
75
Oil Flow Chart
76
Engine Lubrication Specifications
76
Oil Pressure Test
76
Engine Disassembly and Inspection
77
Cylinder Head Assembly Exploded View
77
Rocker Arms
78
Push Rods
78
Cylinder Head Removal
78
Cylinder Head Inspection
79
Cylinder Head Warp
79
Valve Seal/Spring Service
79
(On Engine)
79
Cylinder Head Disassembly
80
Valve Inspection
81
Combustion Chamber
82
Valve Seat Reconditioning
82
Cylinder Head Reassembly
84
Valve Sealing Test
85
Cylinder Removal
85
Valve Lifter Removal/Inspection
85
Piston Removal
86
Cylinder Inspection
87
Piston-To-Cylinder Clearance
88
Piston/Rod Inspection
88
Piston Ring Installed Gap
89
Starter Drive/Bendix Removal Inspection
89
Flywheel / Stator Removal / Inspection
90
Engine Crankcase Disassembly / Inspection
91
Camshaft Inspection
98
Engine Reassembly
99
Crankcase Reassembly
99
Flywheel / Stator Installation
110
Cylinder Head Reassembly
111
Troubleshooting
113
Engine
113
Cooling System
114
Efi Exhaust System (Deluxe)
115
Dual Exhaust Layout
115
Fuel Injection Chapter 4 Fuel Injection
117
Chapter 4
118
General Information
118
Special Tools
118
Service Notes
119
Efi System Exploded View
120
Efi System Component Locations
121
Fuel Lines - Quick Connect
122
Fuel Tank Assembly
122
Electronic Fuel Injection
123
Principal Components
123
Efi Operation Overview
123
Initial Priming / Starting Procedure
123
Electronic Control Unit (Ecu)
124
Operation Overview
124
Ecu Service
124
Ecu Replacement
124
Fuel Pump
125
Operation Overview
125
Fuel Pump Test
125
Fuel Pump / Tank Assembly Replacement
126
Fuel Filters
128
General Information
128
Fuel Filter Service
128
Fuel Filter Replacement
128
Fuel Pressure Regulator
128
Operation Overview
128
Fuel Pressure Regulator Test
128
Fuel Pressure Regulator Replacement
128
Fuel Injectors
129
Operation Overview
129
Fuel Injector Service
129
Fuel Injector Replacement
129
Crankshaft Position Sensor (Cps)
130
Operation Overview
130
Crankshaft Position Sensor Test
130
Crankshaft Position Sensor (Cps) Replacement
130
Temperature / Barometric Air Pressure Sensor (T-Bap)
131
Operation Overview
131
Temperature and Barometric Air Pressure Sensor Test
131
Temperature and Barometric Air Pressure Sensor Replacement
131
Throttle Position Sensor (Tps)
131
Throttle Position Sensor Replacement
131
Throttle Position Sensor Test
132
Throttle Position Sensor Initialization
132
Engine Temperature Sensor
134
Operation Overview
134
Engine Temperature Sensor Test
134
Engine Temperature Sensor Replacement
134
Diagnostics Using "Blink Codes
135
Efi Troubleshooting
136
Troubleshooting
135
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
141
Chapter 5
142
Decal Replacement
142
General Information
142
Special Tools
142
Torque Specifications
142
Plastic Insert Removal / Installation
143
Body
144
Side Panel Removal
144
Front Cover Removal / Installation
144
Foot Well Removal / Installation
145
X2 Foot Well Removal / Installation
145
Front Storage Removal
146
Front Storage Installation
148
Sportsman Rear Rack Removal / Installation
148
Front Cab/Fender Removal/Installation
149
Sportsman Rear Cab / Fender Removal / Installation
150
X2 Rear Quarter Panel Removal / Installation
150
Sportsman Rear Storage Removal / Installation
151
Radiator Screen Removal
151
Sportsman Body Assembly Exploded View
152
X2 Body Assembly Exploded View
153
Body Rack Exploded Views
154
Headlight Pod Exploded View
155
Steering
156
Handlebar Block Installation Procedure
156
Steering / A-Arm Exploded View
157
A-Arm Replacement
158
Ball Joint Replacement
159
Steering Post Removal
160
Steering Post Assembly
160
Suspension
160
Front Strut Cartridge Replacement
160
Strut Assembly
161
Sportsman Rear Suspension Assembly
162
X2 Rear Suspension Exploded View
163
X2 Torsion Bar Exploded View
164
X2 Cargo Box
165
Exploded View
165
Removal / Installation
166
X2 Seat Assembly
168
Exploded Views
168
X2 Seat Operation - Configuring Cargo Box for Passenger Riding
169
Driver Seat Backrest Removal / Installation
170
Passenger Seat Backrest Removal / Installation
170
Clutch System Chapter 6 Clutch System
171
Chapter 6
172
Component Fastener Torques
172
Special Tools
172
Special Tools and Specifications
172
Pvt Exploded Views
173
Pvt Sealing and Ducting Components
173
Drive Clutch Exploded View
173
Engine Braking System (Ebs) Exploded View
175
Pvt System
176
Pvt Operation Overview
176
Drive Clutch Operation
176
Driven Clutch Operation
176
Ebs Clutch Operation
177
Pvt Maintenance / Inspection
177
Drive Clutch Spring
178
Optional Shift Weights
179
Pvt Drying
180
Pvt Disassembly
180
Pvt Installation
181
Drive Belt Removal / Inspection
182
Drive Belt Installation
183
Clutch Alignment
184
Clutch Offset
184
Ebs Drive Clutch Service
185
Drive Clutch Disassembly
185
Spider Removal
185
Button to Tower Clearance Inspection
187
Shift Weight Inspection
187
Drive Clutch Inspection
187
Moveable Sheave Bushing Inspection
188
Drive Clutch Bushing Service
188
One-Way Clutch Inspection (Drive Clutch)
190
Drive Clutch Reassembly
190
Ebs Driven Clutch Service
192
Driven Clutch Disassembly
192
Driven Clutch Bushing Removal/Installation
194
Ebs Driven Clutch Reassembly
195
Standard Drive Clutch
198
Drive Clutch Disassembly
198
Spider Removal
199
Button to Tower Clearance Inspection
200
Shift Weight Inspection
200
Drive Clutch Reassembly
202
Standard Driven Clutch
204
Disassembly
204
Inspection
204
Assembly
205
Pvt Troubleshooting
206
Overheating
206
Problem, Cause and Remedy Chart
207
Final Drive Chapter 7 Final Drive
209
Chapter 7
210
Front Drive Axle
210
Removal
210
Installation
212
Gearcase Fluid / Capacity
210
Special Tools
210
Specifications
210
Torque Table
210
Front Drive Shaft (CV) Boot
212
Inspection
212
Replacement
212
Front Hub
214
Disassembly
214
Assembly
214
Prop Shaft - Front or Rear
215
Removal and Installation
215
U-Joint
215
Disassembly
215
Assembly
216
Drive Axle Exploded Views
218
Drive Shafts and Propshafts
218
Front Gearcase - Centralized Hilliard (Standard Models)
219
Exploded View (Standard Models)
219
Operation
220
Gearcase Removal
220
Disassembly / Inspection
221
Reassembly / Inspection
225
Setting Ring Gear Backlash
226
Front Gearcase Diagnosis
227
Gearcase Installation
228
Front Gearcase - Active Descent Control (Deluxe Models)
229
Adc Gearcase Exploded View (Deluxe Models)
229
Operation
230
Adc Coil Testing
231
Adc Differential Hydraulic Circuit Bleeding
231
Disassembly / Inspection
231
Adc Gearcase Piston Replacement Procedure
235
Assembly
237
Rear Hub
240
Removal
240
Disassembly
241
Assembly
242
Installation
242
Rear Drive (CV) Shaft
243
Removal
243
Service
244
CV Boot Replacement
245
Installation
246
Drive Shaft and CV Joint Handling Tips
247
Rear Gearcase
247
Removal
247
Disassembly and Inspection
247
Reassembly
249
Installation
250
Rear Gearcase Exploded View
251
Sportsman Transmission Chapter 8 Sportsman Transmission
255
Sportsman Transmission
256
Transmission Exploded View
256
Chapter 8 Lubricant / Capacity
258
Specificiatons
258
Transmission Service
258
Transmission Removal
258
Disassembly
259
Assembly
264
Transmission Installation
269
Troubleshooting
270
Table of Contents
271
Sportsman X2 Transmission
272
Transmission Exploded Views
272
Mounting Exploded View
274
Specifications
275
Torque Specifications
275
Special Tools
275
Lubrication
275
Transmission Service
275
Gear Selector Removal
275
Transmission Removal
275
Transmission Installation
277
Troubleshooting Checklist
278
Transmission Disassembly
279
Transmission Assembly
284
Transmission Front Output Shaft Backlash Procedure
285
Brakes Chapter 9 Brakes
291
Chapter 9
292
Component Service Limits
292
Specifications
292
Torque Table
292
Brake System Exploded Views
293
X2 System Component Exploded View
293
Sportsman System Component Exploded View
294
Brake Caliper Exploded Views
295
Sportsman and X2 Front Caliper Assembly
295
X2 Rear Caliper Assembly
295
Sportsman Rear Caliper Assembly
296
Hydraulic Brake System
296
Operation Overview
296
Brake Noise Troubleshooting
297
Brake Bleeding / Fluid Change
297
Front Master Cylinder
299
Removal
299
Installation
299
Front Brakes
300
Pad Removal
300
Assembly
301
Brake Burnishing Procedure
302
Front Brake Disc
302
Inspection
302
Removal / Replacement
303
Front Caliper
304
Removal
304
Inspection
305
Reassembly
305
Installation
306
Rear Brake Pad
307
X2 Pad Removal
307
X2 Pad Installation
308
Sportsman Rear Pad Removal
309
Sportsman Rear Pad Installation
310
Brake Burnishing Procedure
310
X2 Rear Caliper
311
Removal
311
Inspection
312
Reassembly
312
Sportsman Rear Caliper
313
Removal and Inspection
313
Assembly
314
Rear Brake Disc
315
Inspection
315
Rear Master Cylinder
316
X2 Exploded View
316
Overview
317
X2 Rear Master Cylinder Removal and Installation
317
Sportsman Rear Master Cylinder Removal / Installation
318
Pedal Removal and Installation
319
Troubleshooting
319
Brakes Squeal
319
Poor Brake Performance
319
Lever Vibration
319
Caliper Overheats (Brakes Drag)
319
Brakes Lock
319
Chapter 10 Electrical
321
Instrument Cluster
323
Overview
323
Instrument Cluster Diagnostic Mode
324
Setting a New Service Interval
326
Efi Diagnostic Mode
327
Speedometer Removal
328
Speedometer Installation
329
Speedometer Troubleshooting
330
Test 1 - no All Wheel Drive
330
Test 2 - no Display / Test 3 - no Reverse Speed Limit
331
Test 4 - no Awd Hub Safety Limiter
332
Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
333
Test 7 - no Fuel Gauge / Test 8 - Transmission Switch
334
Active Descent Control (Adc) Coil
335
Operation Overview
335
Diagnosing System Failures
335
All Wheel Drive (Awd) Coil
335
Cooling System Components
336
Fan Control Circuit Operation / Testing
336
Fan Control Circuit Bypass Test
336
Coolant Temperature Sensor
336
Fan Motor Current Draw
337
Gear Position Indicator Switch
337
Test Diagram
337
Electronic Throttle Control (Etc) Switch
338
Etc Switch Operation
338
Etc Operation Test
338
Ignition System
339
Flywheel Identification
339
Efi - DC/CDI Ignition Overview
339
Alternator/Ignition Components - 700/800 Efi
340
Crankshaft Position Sensor Gap
341
Ignition System Troubleshooting
341
Charging System
341
Current Draw - Key off
341
Charging System "Break Even" Test
342
Alternator Output Test
342
Charging System Testing Flow Chart
344
Relays
345
Operation
345
Power Relay
345
Fuses/Circuit Breaker
346
Operation
346
Lighting
346
High Beam Headlight Bulb Replacement
346
Headlight Housing Replacement
347
High Beam Headlight Adjustment
348
Lower Headlamp Removal / Installation
348
Low Beam Headlight Adjustment
349
Headlamp Switch Test
349
Sportsman Work Light Switch (Deluxe)
350
Sportsman Brake Light / Work Light (Deluxe) Replacement
350
X2 Brake Light / Work Light (Deluxe) Replacement
351
Brake Light Switch
352
Fuel Sender
353
Testing
353
X2 Differential System
353
Solenoid Testing
353
Solenoid Replacement
353
Differential Relay Operation
354
Differential Relay Testing
354
X2 Speed Sensor
354
Testing
354
Replacement
354
Accessory Power
355
Wire Connections
355
International
356
Starter System
356
700/800 Starter Lockout Overview and Diagnostic
356
800 X2 Starter Lockout Overview and Diagnostic
357
Troubleshooting
358
Voltage Drop Test
358
Starter Motor Removal / Disassembly
358
Brush Inspection / Replacement
359
Armature Testing
360
Starter Reassembly / Installation
361
Starter Solenoid Bench Test
361
Starter Drive
362
Starter Exploded View
363
Starter System Testing Flow Chart
364
Basic Winch Wiring- Pre-Wired Models
365
Battery
366
Battery Identification
366
Battery Activation (Conventional)
366
Battery Terminals/Bolts
367
Conventional Battery Inspection / Removal
367
Conventional Battery Installation
367
Conventional Battery Testing
368
Conventional Battery Ocv - Open Circuit Voltage Test
368
Conventional Battery Specific Gravity Test
368
Battery Load Test
369
Off Season Storage
369
Charging Procedure
369
Low Maintenance Battery
370
Low Maintenance Battery Charging
370
Low Maintenance Battery Inspection / Removal
371
Low Maintenance Battery Installation
371
Low Maintenance Battery - Ocv- Open Circuit Voltage Test
372
Low Maintenance Battery Load Test
372
Low Maintenance Battery Off-Season Storage
373
Low Maintenance Battery Charging Procedure
373
800 Efi International Brake System
376
Chapter 11 Overview
376
800 Efi International Steering Post and Lock Assembly
378
Steering Assembly Exploded View
378
800 Efi International Electrical
379
Turn / Hazard Signal Diagram
379
4
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Polaris 2007 SPORTSMAN X2 800 Specifications
General
Brand
Polaris
Model
2007 SPORTSMAN X2 800
Category
Offroad Vehicle
Language
English
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