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2008 sportsman 800efi
Polaris 2008 sportsman 800efi User Manual
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5.30
BODY / STEERING / SUSPENSION
X2 SEAT ASSEMBLY
Exploded Views
169
171
Table of Contents
General Information Chapter 1 1
5
Table of Contents
5
Chapter 1
6
Engine and Machine Serial Numbers
6
Engine Designation Numbers
6
General Information
6
Model Information
6
Model Number
6
Transmission I.D. Location
6
Vin Identification
6
Paint Codes
7
Publications
7
Replacement Keys
7
2008 Sportsman 800 Efi
8
Model Number: A08Mn76Af, Al, Aq, As, Ax
8
2008 Sportsman X2 700 Efi
10
Model Number: A08Tn68Az, Ax
10
2008 Sportsman Touring 800 Efi
12
Model Number: A08Dn76Af, Ag, Ah, Al, Al, as / A08Dn76Fc, Fh
12
Misc. Numbers/Charts
14
Standard Torque Specifications
14
Special Tools
14
Sae Tap Drill Sizes
15
Metric Tap Drill Sizes
15
General
16
Conversion Table
16
Glossary of Terms
17
Maintenance Chapter 2 Maintenance 2
19
Chapter 2
21
Maintenance
21
Maintenance Chart Key
21
Overview
21
Periodic Maintenance Chart
22
Lubrication / Fluids
25
Sportsman Component Locations
25
Sportsman X2-Touring Component Locations
26
Polaris Lubricants, Maintenance and Service Products
27
Polaris Lubricant Symbol Identification
28
Pre-Ride / Daily Inspection
28
Lubrication / Grease Points
29
Front Gearcase Lubrication
30
Rear Gearcase Lubrication - 800 Efi
31
Transmission Lubrication
32
Adc Differential Hydraulic Circuit Fluid Change
33
Vehicle Inspection
33
Shift Link Rod Inspection
33
Throttle Inspection
34
Throttle Cable / Electronic Throttle Control Adjustment
34
Fuel System
35
Electrical
35
Vent Lines
35
Compression Test
35
Engine Mounts
36
Spark Plug
36
Active Descent Control (Adc) Reservoir Level
36
Battery Maintenance
37
Cooling System
37
Coolant Strength / Type
38
Cooling Hoses
38
Radiator
38
Cooling System Pressure Test
38
Reservoir Level Inspection
38
Radiator Coolant Level
39
Air Filter Service
39
Air Box Sediment Tube
40
Engine Breather Hose
40
Pvt Inspection / Drying Procedure
41
Engine Ground
41
Engine Oil Level
41
Oil/Filter Change
42
Steering Inspection
43
Tie Rod / Steering
43
Camber/Caster
43
Wheel Alignment
44
Toe Alignment
44
Exhaust Pipe
45
Brake System Inspection
45
Brake Pads
46
Brake Hose Inspection
46
Auxiliary (Rear) Brake Test
46
Auxiliary Brake Adjustment
47
Suspension: Spring Preload Adjustment
47
Front Suspension
47
Rear Suspension
47
CV Shaft Boot Inspection
47
Atv Controls
48
Wheel Inspection
48
Wheel Installation
48
Wheel Removal: Front or Rear
48
Frame, Nuts, Bolts, Fasteners
49
Front / Rear Storage Compartments
49
Tire Inspection
49
Tire Pressure
49
Winch Operation (if Equipped)
50
Cleaning and Storage of Atv
52
Maintenance Schedule
55
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
Clutch
73
Engine Installation Notes
74
Cylinder Hone Selection and Honing Procedure
74
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 (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
800 Efi Exhaust System
115
Dual Exhaust Layout
115
Fuel Injection Chapter 4 Fuel Injection
117
Chapter 4
118
General Information
118
Special Tools
118
Service Notes
120
Efi System Exploded View
121
Efi System Component Locations
122
Fuel Lines - Quick Connect
123
Fuel Tank Assembly
123
Electronic Fuel Injection
124
Principal Components
124
Efi Operation Overview
124
Initial Priming / Starting Procedure
124
Electronic Control Unit (Ecu)
125
Operation Overview
125
Ecu Service
125
Ecu Replacement
125
Fuel Pump
126
Operation Overview
126
Fuel Pump Test
126
Fuel Pump / Tank Assembly Replacement
127
Fuel Filter
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
Efi Circuit - Power on
137
Efi Circuit - Crank Position Sensor
137
Efi Circuit - Fuel Pump
138
Efi Circuit - Throttle Position Sensor
138
Efi Circuit - Temperature - Barometric Air Pressure Sensor
139
Efi Circuit - Engine Temperature
139
Efi Circuit - Malfunction Indicator Light
140
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-Touring 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- Touring Body Assembly Exploded View
153
Touring Body/Rack Assembly Exploded View
154
Body / Rack Exploded Views
155
Touring Body/Seat Assembly Exploded View
156
Headlight Pod Exploded View
157
Steering
158
Handlebar Block Installation Procedure
158
Steering / A-Arm Exploded View
159
A-Arm Replacement
160
Ball Joint Replacement
161
Steering Post Removal
162
Steering Post Assembly
162
Suspension
162
Front Strut Cartridge Replacement
162
Strut Assembly
163
Sportsman Rear Suspension Assembly
164
X2- Touring Rear Suspension Exploded View
165
X2 Torsion Bar Exploded View
166
X2 Cargo Box
167
Exploded View
167
Removal / Installation
168
X2 Seat Assembly
170
Exploded Views
170
X2 Seat Operation - Configuring Cargo Box for Passenger Riding
171
X2 Driver Seat Backrest Removal / Installation
172
X2 Passenger Seat Backrest Removal / Installation
172
Clutch System Chapter 6 Clutch System
175
Chapter 6
176
Component Fastener Torques
176
Special Tools
176
Special Tools and Specifications
176
Pvt Exploded Views
177
Pvt Sealing and Ducting Components
177
Drive Clutch Exploded Views (Ebs Vs. Non-Ebs)
177
Driven Clutch Exploded Views
178
Engine Braking System (Ebs) Exploded View
179
Pvt System
180
Pvt Operation Overview
180
Drive Clutch Operation
180
Driven Clutch Operation
180
Ebs Clutch Operation
181
Pvt Maintenance / Inspection
181
Drive Clutch Spring
182
Optional Shift Weights
183
Pvt Drying
184
Pvt Disassembly
184
Pvt Installation
185
Drive Belt Removal / Inspection
186
Drive Belt Installation
187
Clutch Alignment
188
Clutch Offset
188
Ebs Drive Clutch Service
189
Drive Clutch Disassembly
189
Spider Removal
189
Button to Tower Clearance Inspection
191
Shift Weight Inspection
191
Drive Clutch Inspection
191
Moveable Sheave Bushing Inspection
192
Drive Clutch Bushing Service
192
One-Way Clutch Inspection (Drive Clutch)
194
Drive Clutch Reassembly
194
Ebs Driven Clutch Service
196
Driven Clutch Disassembly
196
Driven Clutch Bushing Removal/Installation
198
Ebs Driven Clutch Reassembly
199
Pvt Troubleshooting
203
Overheating
203
Problem, Cause and Remedy Chart
204
Final Drive Chapter 7 Final Drive
207
Final Drive
207
Chapter 7
208
Front Hub
208
Disassembly
208
Assembly
209
Gearcase Fluid / Capacity
208
Special Tools
208
Specifications
208
Torque Table
208
Front Drive Shaft (CV) Service
209
Removal
209
Installation
210
Inspection
211
CV Joint/Boot Replacement
211
Prop Shaft - Front or Rear
213
Removal and Installation
213
U-Joint
213
Disassembly
213
Assembly
214
Drive Axle Exploded Views
216
Drive Shafts and Propshafts
216
Front Gearcase - Centralized Hilliard W/ Active Descent Control
217
Operation
217
Adc Gearcase Exploded View
218
Adc Operation
219
Front Gearcase Diagnosis
220
Gearcase Removal
221
Gearcase Installation
222
Coil Testing
223
Adc Differential Hydraulic Circuit Bleeding
223
Disassembly / Inspection
223
Adc Gearcase Piston Replacement Procedure
227
Assembly
229
Setting Ring Gear Backlash
232
Rear Hub
233
Removal
233
Disassembly
234
Assembly
235
Installation
235
Rear Drive (CV) Shaft
236
Removal
236
Service
237
CV Boot Replacement
238
Installation
239
Drive Shaft and CV Joint Handling Tips
239
Rear Gearcase
240
Removal
240
Disassembly and Inspection
240
Reassembly
241
Installation
242
Rear Gearcase Exploded View
244
Sportsman Transmission Chapter 8 Sportsman Transmission
247
Chapter 8 Sportsman Transmission
248
Transmission Exploded View
248
Specificiatons
250
Torque Specifications
250
Lubricant / Capacity
250
Transmission Service
250
Transmission Removal
250
Disassembly
251
Assembly
256
Transmission Installation
261
Troubleshooting
262
X2 / Touring Transmission Chapter 8 X2 / Touring Transmission
263
Transmission Exploded Views
264
Transmission Exploded View
264
Mounting Exploded View
266
Specifications
267
Torque Specifications
267
Special Tools
267
Lubrication
267
Transmission Service
267
Gear Selector Removal
267
Transmission Removal
267
Transmission Installation
269
Troubleshooting Checklist
270
Transmission Disassembly
271
Transmission Assembly
276
Transmission Front Output Shaft Backlash Procedure
277
Brakes Chapter 9 Brakes
283
Chapter 9
284
Component Service Limits
284
Specifications
284
Torque Table
284
Brake System Exploded Views
285
X2, Touring System Component Exploded View
285
Sportsman System Component Exploded View
286
Brake Caliper Exploded Views
287
Sportsman and X2, Touring Front Caliper Assembly
287
X2, Touring Rear Caliper Assembly
287
Sportsman Rear Caliper Assembly
288
Hydraulic Brake System
288
Operation Overview
288
Brake Noise Troubleshooting
289
Brake Bleeding / Fluid Change
289
Front Master Cylinder
291
Removal
291
Installation
291
Front Brakes
292
Pad Removal
292
Assembly
293
Brake Burnishing Procedure
294
Front Brake Disc
294
Inspection
294
Removal / Replacement
295
Front Caliper
296
Removal
296
Inspection
297
Reassembly
297
Installation
298
Rear Brake Pad
299
X2, Touring Pad Removal
299
X2, Touring Pad Installation
300
Sportsman Rear Pad Removal
301
Sportsman Rear Pad Installation
302
Brake Burnishing Procedure
302
X2, Touring Rear Caliper
303
Removal
303
Inspection
304
Reassembly
304
Sportsman Rear Caliper
305
Removal and Inspection
305
Assembly
306
Rear Brake Disc
307
Inspection
307
Rear Master Cylinder
308
X2, Touring Exploded View
308
Overview
309
X2, Touring Rear Master Cylinder Removal and Installation
309
Sportsman Rear Master Cylinder Removal / Installation
310
Pedal Removal and Installation
311
Troubleshooting
311
Chapter 10 Electrical
313
Instrument Cluster
315
Overview
315
Instrument Cluster Diagnostic Mode
316
Setting a New Service Interval
318
Efi Diagnostic Mode
319
Speedometer Removal
320
Speedometer Installation
321
Speedometer Troubleshooting
322
Test 1 - no All Wheel Drive
322
Test 2 - no Display / Test 3 - no Reverse Speed Limit
323
Test 4 - no Awd Hub Safety Limiter
324
Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
325
Test 7 - no Fuel Gauge / Test 8 - Transmission Switch
326
Active Descent Control (Adc) Coil
327
Operation Overview
327
Diagnosing System Failures
327
All Wheel Drive (Awd) Coil
327
Cooling System Components
328
Fan Control Circuit Operation / Testing
328
Fan Control Circuit Bypass Test
328
Coolant Temperature Sensor
328
Fan Motor Current Draw
329
Gear Position Indicator Switch
329
Test Diagram
329
Electronic Throttle Control (Etc) Switch
330
Etc Switch Operation
330
Etc Operation Test
330
Ignition System
331
Flywheel Identification
331
Efi - DC/CDI Ignition Overview
331
Alternator/Ignition Components - 700/800 Efi
332
Crankshaft Position Sensor Gap
333
Ignition System Troubleshooting
333
Charging System
333
Current Draw - Key off
333
Charging System "Break Even" Test
334
Alternator Output Test
334
Charging System Testing Flow Chart
336
Relays
337
Operation
337
Power Relay
337
Fuses/Circuit Breaker
338
Operation
338
Lighting
338
High Beam Headlight Bulb Replacement
338
Headlight Housing Replacement
339
High Beam Headlight Adjustment
340
Lower Headlamp Removal / Installation
340
Low Beam Headlight Adjustment
341
Headlamp Switch Test
341
Work Light / Differential Switch
342
Sportsman / Touring Brake Light / Work Light Replacement
342
X2 Brake Light / Work Light Replacement
343
Brake Light Switch
344
Testing
345
Fuel Sender
345
X2 / Touring Differential System
345
Solenoid Testing
345
Solenoid Replacement
345
Differential Relay Operation
346
Differential Relay Testing
346
X2 / Touring Speed Sensor
346
Testing
346
Replacement
346
Accessory Power
347
Wire Connections
347
Starter System
348
Sportsman Starter Lockout Overview and Diagnostic
348
X2 /Touring Starter Lockout Overview and Diagnostic
349
Troubleshooting
350
Voltage Drop Test
350
Starter Motor Removal / Disassembly
350
Brush Inspection / Replacement
351
Armature Testing
352
Starter Reassembly / Installation
353
Starter Solenoid Bench Test
353
Starter Drive
354
Starter Exploded View
355
Starter System Testing Flow Chart
356
Basic Winch Wiring- Pre-Wired Models
357
Battery
358
Battery Identification
358
Battery Activation (Conventional)
358
Battery Terminals/Bolts
359
Conventional Battery Inspection / Removal
359
Conventional Battery Installation
359
Conventional Battery Testing
360
Conventional Battery Ocv - Open Circuit Voltage Test
360
Conventional Battery Specific Gravity Test
360
Battery Load Test
361
Off Season Storage
361
Charging Procedure
361
Low Maintenance Battery
362
Low Maintenance Battery Charging
362
Low Maintenance Battery Inspection / Removal
363
Low Maintenance Battery Installation
363
Low Maintenance Battery - Ocv- Open Circuit Voltage Test
364
Low Maintenance Battery Load Test
364
Low Maintenance Battery Off-Season Storage
365
Low Maintenance Battery Charging Procedure
365
Troubleshooting Diagrams
366
Overview
366
All Wheel Drive - Efi
366
Charging Circuit - Efi
366
Cooling Fan - Efi
367
Fuel Pump - Efi
367
Gear Switch - Efi
368
Power Circuit - Efi
368
Reverse Override - Efi
369
Fan Control - Efi
369
Start Circuit - Efi
370
Start Enable - Efi
370
International
371
800 Touring Efi International Brake System
372
Chapter 11
372
Overview
372
Exploded View
373
800 Touring Efi International Steering Post and Lock Assembly
374
Steering Assembly Exploded View
374
800 Touring Efi International Electrical
375
Turn / Hazard Signal Diagram
375
4
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Polaris 2008 sportsman 800efi Specifications
General
Brand
Polaris
Model
2008 sportsman 800efi
Category
Offroad Vehicle
Language
English
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