Polaris Sportsman 700/800/800 X2 EFI Repair Service Manual 2007

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This workshop repair service manual PDF download for the 2007 Polaris Sportsman 700/800/800 X2 EFI has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

2007 SPORTSMAN 700 EFI
MODEL NUMBER: A07MH68AX, AY, AZ
(Standard Model Only)
ENGINE MODEL: EH068OLE

2007 SPORTSMAN 800 EFI
MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA
(Standard) (Deluxe) (International)
ENGINE MODEL: EH076OLE

2007 SPORTSMAN X2 800 EFI
MODEL NUMBER: A07TH76AU, A07TN76AF
(Standard) (Deluxe)
ENGINE MODEL: EH076OLE


TABLE OF CONTENTS :

FOREWORD
CHAPTER INDEX
CH 1 - GENERAL INFORMATION
CH 2 - MAINTENANCE 
CH 3 - ENGINE
CH 4 - FUEL INJECTION
CH 5 - BODY/STEERING/SUSPENSION
CH 6 - CLUTCH SYSTEM
CH 7 - FINAL DRIVE
CH 8 - TRANSMISSION / SPORTSMAN
CH 8 - TRANSMISSION / X2
CH 9 - BRAKES
CH 10 - ELECTRICAL
CH 11 - INTERNATIONAL
INDEX
WIRE DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9920378
Total Pages : 393


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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FOREWORD
    understanding manual safety labels and directions
    TRADEMARKS
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
        MODEL NUMBER: A07MH68AX, AY, AZ 
    2007 SPORTSMAN 800 EFI
    Specifications, Sportsman 800 EFI
        MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA
    2007 SPORTSMAN X2 800 EFI
    Specifications, Sportsman 800 X2 EFI
        MODEL NUMBER: A07TH76AU, A07TN76AF
    Misc. Tables
    MISC. NUMBERS/CHARTS
        Standard Torque Specifications
        Specification, Standard Fastener Torques
        SPECIAL TOOLS
        SAE Tap Drill Sizes
        Specification, Drill and Tap Sizes
        Metric Tap Drill Sizes
        Decimal Equivalents
        Conversion Table
        Conversion Table
        Glossary Of Terms
        Glossary of Terms
        
CH 2 - MAINTENANCE 
    MAINTENANCE
    Maintenance Chart, Periodic
        Overview
        Periodic Maintenance Chart
    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
            Specification, Wheel Toe-Out
        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
            Specifications, Engine Oil Pressure
    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
            Specification, Cylinder Head Warp
        Valve Seal/Spring Service (On Engine)
        Valve Seal/Spring Service
        Engine Valve Seal/Spring Service
        Cylinder Head Disassembly
        Cylinder Head Disassembly
            Specification, Valve Spring Free Length
        Valve Inspection
        Engine  Valve Inspection
            Specification, Valve Stem Diameter
            Specification, Valve Stem Guide I.D.
        Combustion Chamber
        Combustion Chamber
        Valve Seat Reconditioning
        Valve Seat Reconditioning
        Engine  Valve Seat Reconditioning
            Specification, Valve Seat Contact Width
        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
            Specification, Cylinder Warp Limit
            Specification, Cylinder Taper Limit
        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
            Specification, Cam Lobe Height
            Specifications, Cam Shaft
    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
        Engine
        Engine Troubleshooting
        Cooling System
        Engine Cooling System Troubleshooting
    800 EFI Exhaust System (DELUXE)
        Dual Exhaust Layout
        Exhaust Breakdown, Sportsman 800 EFI
        Exhaust, Dual 800 EFI
        
CH 4 - FUEL INJECTION
    GENERAL INFORMATION
        Special Tools
        Fuel Injection, Special Tools
        Service Notes
        Fuel Injection, Service Notes
        EFI System Exploded View
        Fuel Injection, Exploded View
        EFI System Component Locations
        Fuel Injection, Component Locations
        Fuel Tank Assembly
        Fuel Tank Location
        Fuel Lines - Quick Connect
    ELECTRONIC FUEL INJECTION
        Principal Components
        EFI Operation Overview
        EFI Operation Overview
        Initial Priming / Starting Procedure
        EFI Priming / Starting Procedure
    ELECTRONIC CONTROL UNIT (ECU)
        Operation Overview
        Electronic Control Unit (ECU)
        ECU Service
        ECU Replacement
    FUEL PUMP
        Operation Overview
        Fuel Pump / Tank Assembly
        Fuel Pump Test
        Fuel Pump / Tank Assembly Replacement
    FUEL PRESSURE REGULATOR
        Operation Overview
        Fuel Pressure Regulator
        Fuel Pressure Regulator Test
        Fuel Pressure Regulator Replacement
    FUEL FILTERS
        General Information
        Fuel Filter
        Fuel Filter Service
        Fuel Filter Replacement
    FUEL INJECTORS
        Operation Overview
        Fuel Injector
        Fuel Injector Service
        Fuel Injector Replacement
    CRANKSHAFT POSITION SENSOR (CPS)
        Operation Overview
        Crankshaft Position Sensor (CPS)
        Crankshaft Position Sensor Test
        Crankshaft Position Sensor (CPS) Replacement
    TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
        Operation Overview
        Temperature / Barometric Air Pressure Sensor (T-Bap)
        Temperature and Barometric Air Pressure Sensor Test
        Temperature and Barometric Air Pressure Sensor Replacement
    THROTTLE POSITION SENSOR (TPS)
        Operation Overview
        Throttle Position Sensor
        Throttle Position Sensor Replacement
        Throttle Position Sensor Replacement
        Throttle Position Sensor Test
        Throttle Position Sensor Initialization
        Throttle Position Sensor Initialization
    ENGINE TEMPERATURE SENSOR
        Operation Overview
        Engine Temperature Sensor
        Engine Temperature Sensor Test
        Engine Temperature Sensor Test
        Engine Temperature Sensor Replacement
        Engine Temperature Sensor Replacement
    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
        Torque Specifications
        Specifications, Body and Steering Torque Values
        Body and Steering Torque Values
        Steering Torque Values
        Special Tools 
        Special Tools, Body & Steering
        Decal Replacement
        Decal Replacement
        Plastic Insert Removal / Installation
        Plastic Inserts
    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
        Handlebar Block Installation Procedure
        Handlebar Block Installation Procedure
        Steering / A-arm Exploded View
        Steering A-Arm Exploded View
        A-Arm Replacement
        A-Arm Replacement
        Ball Joint Replacement
        Ball Joint Replacement, Front
        Steering Post Removal
            Steering Post Removal
        Steering Post Assembly
        Steering Post Assembly
    SUSPENSION
        Front Strut Cartridge Replacement
        Strut Cartridge Replacement, Front
        Strut Assembly
        Strut  Assembly
        Sportsman Rear Suspension Assembly
        Rear Suspension Assembly
        X2 Rear Suspension Exploded View
        Rear Suspension Assembly
        X2 Torsion Bar Exploded View
    X2 CARGO BOX
        Exploded View
        Removal / Installation
        Cargo Box, Removal and Installation
    X2 SEAT assembly
        Exploded Views
        X2 Seat Operation - Configuring Cargo Box For Passenger Riding
        Passenger Seat, Operation
        Driver Seat Backrest Removal / Installation
        X2, Seat Disassembly
        Passenger Seat Backrest Removal / Installation
        
CH 6 - CLUTCH SYSTEM
    SPECIAL TOOLS AND SPECIFICATIONS
        Special Tools
        PVT Special Tools
        Component Fastener Torques
        PVT Torque Specs
        Specification, PVT Component Torque Table
    PVT EXPLODED VIEWS
        PVT Sealing And Ducting Components
        PVT Ducting
        Drive Clutch Exploded Views (Standard and Deluxe)
        PVT, Drive Clutch Exploded View
        Driven Clutch Exploded Views (Standard and Deluxe)
        EBS Exploded View
        Engine Braking System (EBS) Exploded View
        EBS Exploded View
    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
            Specification, PVT Drive Belt Width
            Specification, PVT Center-to-Center Distance
        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
        Driven Clutch Disassembly 
        PVT, Driven Clutch Disassembly
        DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION
        PVT, Driven Clutch Bushing Service
        EBS DRIVEN CLUTCH REASSEMBLY
        PVT, Driven Clutch Reassembly
    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
        Disassembly
        Inspection
        Assembly
    PVT TROUBLESHOOTING
    Clutch, Troubleshooting
        Overheating
        PVT Overheating Chart
        Problem, Cause and Remedy Chart
        PVT Troubleshooting Chart
        
CH 7 - FINAL DRIVE
    SPECIFICATIONS
        Torque Table
        Specifications, Final Drive Torque Values
        Final Drive Torque Specifications
        Special Tools
        Special Tools, Final Drive
        Gearcase Fluid / Capacity
        Specifications, Front Gearcase Lubrication Type/Capacity
        Gearcase, Front Capacity and Fluid Type
    FRONT DRIVE AXLE
        Removal
        Front Drive Axle Removal
        Installation
        Front Drive Axle Installation
    FRONT DRIVE SHAFT (CV) BOOT
        Inspection
        Drive Shaft Boot Inspection
        Replacement
        CV Boot, Replacement
    FRONT HUB
        Disassembly
        Front Hub, Disassembly
        Assembly
        Front Hub, Assembly
    PROP SHAFT - FRONT OR REAR
        Removal and Installation
        Propshaft, Removal
    U-JOINT
    U-joint, Disassembly and Assembly
        Disassembly
        Assembly
    DRIVE AXLE EXPLODED VIEWS
        Drive Shafts and Propshafts
    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
            Front Gearcase Coil Resistance
        Reassembly / Inspection
        Front Gearcase, Reassembly / Inspection
            Front Gearcase - Back Lash Pad Adjustment
        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
            Front Gearcase Coil Resistance
        ADC Gearcase Piston Replacement Procedure
        ADC Gearcase Piston Service
        Assembly
        Front Gearcase, Reassembly
    REAR HUB
        Removal
        Disassembly
        Assembly
        Installation
    REAR DRIVE (CV) SHAFT
        Removal
        Service
        CV Boot Replacement
        INSTALLATION
        Drive Shaft and CV Joint Handling Tips
    REAR GEARCASE
        Removal
        Rear Gearcase, Removal
        Disassembly and Inspection
        Rear Gearcase, Disassembly
        Reassembly
        Rear Gearcase, Assembly
        Installation 
        Rear Gearcase, Installation
        Rear Gearcase Exploded View
        Rear Gearcase, Exploded View
    sPORTSMAN 8.3-8.18
    sPORTSMAN X2 8.19-8.38
    
CH 8 - TRANSMISSION / SPORTSMAN
    TRANSMISSION EXPLODED VIEW
        Sportsman Transmission 
        Transmission Exploded View
    SPECIFICIATONS
        Torque Specifications
        Lubricant / Capacity
    TRANSMISSION SERVICE
        Transmission Removal
        Transmission Gear Selector Removal
        Transmission Removal
        Disassembly
        Transmission Disassembly
        Assembly
        Transmission Assembly
        Transmission Installation
        Transmission Installation
        Troubleshooting
        Transmission Troubleshooting
        
CH 8 - TRANSMISSION / X2
    Transmission
        TRANSMISSION EXPLODED VIEWS
            X2 Transmission Exploded View
            Transmission, Exploded View
            X2 Mounting Exploded View
            Transmission Mounts, Exploded View
        sPECIFICATIONS
            Torque Specifications
            Special Tools
            Transmission, Special Tools
            Lubrication
        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
                Specification, Transmission Silent Chain Length
                
CH 9 - BRAKES
    SPECIFICATIONS
        Torque Table
        Brake, Torque Specifications
        Specifications, Brake Component Torque Values
        Component Service Limits
        Specifications, Brake Component Service Limits
    BRAKE SYSTEM Exploded Views
    Brake System Exploded Views
        X2 System Component Exploded View
        Brake System Components, X2
        Sportsman System Component Exploded View
        Brake System Components, Std, Sportsman
    BRAKE CALIPER EXPLODED VIEWS
    Brake Caliper Exploded View
        Sportsman and X2 Front Caliper Assembly
        X2 Rear Caliper Assembly
        Sportsman Rear Caliper Assembly
    HYDRAULIC BRAKE SYSTEM
    Hydraulic Brake System Operation Overview
        Operation Overview
        Brakes, Operation Overview
        Brake Noise Troubleshooting
        Brake Noise Troubleshooting
        Brake Bleeding / Fluid Change
        Brake Bleeding
    FRONT MASTER CYLINDER
    Brake,  Master Cylinder Removal
        Removal
        Installation
    FRONT BRAKES
    Brake Pad, Removal and Installation
        Pad Removal
        Assembly
        Brake Burnishing Procedure
        Brake Burnishing Procedure
    FRONT BRAKE DISC
    Brake Disc, Front
        Inspection
        Removal / Replacement
    FRONT CALIPER
    Brake Caliper, Front
        Removal
        Inspection
        Reassembly
        Installation
    REAR BRAKE PAD
    Brake Pad, Rear
        X2 Pad Removal
        X2 Pad Installation
        Sportsman Rear Pad Removal
        Brake Pad Removal, Rear
            Specification, Brake Pad Thickness
        Sportsman Rear Pad Installation
        Brake Pad Install, Rear
        Brake Burnishing Procedure
    X2 REAR CALIPER
    Brake Caliper Removal, Rear
        Removal
        Inspection
        Reassembly
    Sportsman REAR CALIPER
        Removal and Inspection
        Brake Caliper Removal, Rear
        Assembly
        Brake Caliper, Assembly
    REAR BRAKE DISC
    Brake Disc, Inspection
        Inspection
            Specification, Brake Disc Thickness
            Specification, Brake Disc Service Limit
    REAR MASTER CYLINDER
    Brake, Rear Auxiliary Master Cylinder
        X2 Exploded View
        Rear Master Cylinder, Exploded View
        Overview
        X2 Rear Master Cylinder Removal and Installation
        Sportsman Rear Master Cylinder Removal / Installation
        Brake, Rear Auxiliary Brake
        Pedal Removal and Installation
    TROUBLESHOOTING
    Brakes, Troubleshooting
        Brakes Squeal
        Poor Brake Performance
        Lever Vibration
        Caliper Overheats (Brakes Drag)
        Brakes Lock
        
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
        Test 1 - No All Wheel Drive
        Speedometer Troubleshooting Tests
        TEST 2 - No Display / TEST 3 - No Reverse Speed Limit
        TEST 4 - No AWD Hub Safety Limiter
        TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor 
        TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch
    ACTIVE DESCENT CONTROL (ADC) COIL
    Active Descent Control (ADC) Coil
        Operation Overview
        Diagnosing System Failures
    ALL WHEEL DRIVE (AWD) COIL
    All Wheel Drive (AWD) Coil
        Operation Overview
        Diagnosing System Failures
    COOLING SYSTEM COMPONENTS
        Fan Control Circuit Operation / Testing
        Fan Control Circuit Operation
        Fan Control Circuit Bypass Test
        Fan Control Circuit Operation / Testing
        Coolant Temperature Sensor
        Specification, Coolant Sensor Resistance
        Fan Motor Current Draw
        Fan Motor Current Draw
    GEAR POSITION INDICATOR SWITCH
        Test Diagram
        Gear Position Indicator Switch Test
    ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
        ETC Switch Operation
        ETC Switch Operation
        ETC Operation Test
        ETC Operation Test
    IGNITION SYSTEM
        Flywheel Identification
        Flywheel ID
        EFI - DC/CDI Ignition Overview
        Ignition Curve
        Alternator/Ignition Components - 700/800 EFI
        Alternator / Ignition Components
        Crankshaft Position Sensor Gap
        Crank Position Sensor Gap
        Ignition System Troubleshooting
        Ignition System Troubleshooting
    CHARGING SYSTEM
        Current Draw - Key Off
        Current Draw  - Key Off Test
        Charging System “Break Even” Test
        Charging System - Break Even Test
        Alternator Output Test
        Alternator Output Test
        Charging System Testing Flow Chart
        Charging System Flow Chart
    RELAYS
        Operation
        Relays
    FUSES/Circuit Breaker
        Operation
        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
            Lower Headlamp Housing 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
        Testing
        Fuel Sender Test
    X2 DIFFERENTIAL System
        Solenoid Testing
        Solenoid, Differential
        Differential Solenoid
        Specification, Differential Solenoid Resistance
        Solenoid Replacement
            Specification, Differential Solenoid Torque
        Differential Relay Operation
        Differential Relay Testing
    X2 SPEED SENSOR
        Testing
        Speed Sensor
        Special Tools, Speed Sensor
        Specification,  Speed Sensor Bolt Torque
        Specification, Differential Solenoid Resistance
        Replacement
        Speedometer Sensor, Replacement
            Specification, Differential Solenoid Torque
    ACCESSORY POWER
        Wire Connections
        Accessory Power Wiring
    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
        Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test
        Starter System Flow Chart
    BASIC WINCH WIRING- PRE-WIRED MODELS
        Winch, Basic Wiring Diagram
    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
    800 EFI International BRAKE SYSTEM
    Brake System Overview, International
        Overview
        Exploded View
        Brake System Exploded View, International
    800 EFI International Steering Post and lock Assembly
        Steering Lock, Exploded View
        Steering Assembly Exploded View
    800 EFI INTERNATIONAL ELECTRICAL
        Turn / Hazard Signal Diagram
        
INDEX
WIRE DIAGRAMS

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