Polaris Sportsman X2 700 /800 EFI /800 Touring Repair Service Manual 2008

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This workshop repair service manual PDF download for the 2008 Polaris Sportsman X2 700 /800 EFI /800 Touring 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 :

2008 SPORTSMAN 800 EFI
MODEL NUMBER: A08MN76AF, AL, AQ, AS, AX
ENGINE MODEL: EH076OLE

2008 SPORTSMAN X2 700 EFI
MODEL NUMBER: A08TN68AZ, AX
ENGINE MODEL: EH068OLE

2008 SPORTSMAN TOURING 800 EFI
MODEL NUMBER: A08DN76AF, AG, AH, AL, AL, AS / A08DN76FC, FH
(Domestic) (International)
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 AND TOURING
CH 9 - BRAKES
CH 10 - ELECTRICAL
CH 11 - INTERNATIONAL TOURING
INDEX
WIRE DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921323
Total Pages : 388


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
    FOREWORD
    understanding manual safety labels and directions
    TRADEMARKS
CHAPTER INDEX

CH 1 - GENERAL INFORMATION
    MODEL INFORMATION
        Model Number
        Engine Designation Numbers
        VIN Identification
        TRANSMISSION I.D. LOCATION
        Engine and Machine Serial Numbers
        PUBLICATIONS
        PAINT CODES
        REPLACEMENT KEYS
    2008 SPORTSMAN 800 EFI
        MODEL NUMBER: A08MN76AF, AL, AQ, AS, AX
    2008 SPORTSMAN X2 700 EFI
        MODEL NUMBER: A08TN68AZ, AX
    2008 SPORTSMAN TOURING 800 EFI
        MODEL NUMBER: A08DN76AF, AG, AH, AL, AL, AS / A08DN76FC, FH
    MISC. NUMBERS/CHARTS
        Standard Torque Specifications
        SPECIAL TOOLS
        SAE Tap Drill Sizes
        Metric Tap Drill Sizes
        Decimal Equivalents
        Conversion Table
        Glossary Of Terms
        
CH 2 - MAINTENANCE
    MAINTENANCE
        Overview
        Periodic Maintenance Chart
    LUBRICATION / FLUIDS
        SPORTSMAN Component Locations
        SPORTSMAN X2-Touring Component Locations
        Polaris Lubricants, Maintenance and Service Products
        Polaris Lubricant Symbol Identification
        Pre-Ride / Daily Inspection
        Lubrication / Grease Points
        Front Gearcase Lubrication
        Rear Gearcase Lubrication - 800 EFI
        Transmission Lubrication 
        ADC Differential Hydraulic Circuit Fluid Change
    VEHICLE INSPECTION
        Shift Link Rod Inspection
        Throttle Inspection
        Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
        Fuel System
        Vent Lines
        Compression Test
        Engine Mounts
        Spark Plug 
        Active Descent Control (ADC) Reservoir Level
        Battery Maintenance
        Cooling System
        Coolant Strength / Type
        Cooling Hoses
        Radiator
        Cooling System Pressure Test
        Reservoir Level Inspection
        Radiator Coolant Level
        Air Filter Service
        Air Box Sediment Tube
        Engine Breather Hose
        PVT Inspection / Drying Procedure
        Engine Ground
        Engine Oil Level
        Oil/filter Change
        Steering Inspection
        Tie Rod / Steering
        Camber/Caster
        Wheel Alignment
        Toe Alignment
        Exhaust Pipe
        Brake System Inspection
        Brake Pads
        Brake Hose Inspection
        Auxiliary (Rear) Brake Test
        Auxiliary Brake Adjustment
        Suspension: Spring Preload Adjustment
        Front Suspension
        Rear Suspension
        CV Shaft Boot Inspection
        ATV Controls
        Wheel Inspection
        Wheel Removal: Front Or Rear
        Wheel Installation
        Tire Pressure
        Tire Inspection
        Frame, Nuts, Bolts, Fasteners
        Front / Rear Storage Compartments
        Winch Operation (If Equipped)
        Cleaning And Storage Of ATV
        Maintenance Schedule
        Maintenance Schedule
        
CH 3 - ENGINE
    SPECIFICATIONS
        Crankcase Exploded Views
        Engine Fastener Torque Patterns
        Torque Specifications
        700/800 EFI Engine Service Specifications
        Special Tools
    GENERAL ENGINE SERVICE
        Accessible Components
        Piston Identification
        Cooling System Specifications
        Cooling System Pressure Test
        Four Stroke - Coolant Air Bleeding Procedure
        Engine Removal (Typical)
        Engine Installation Notes
        Cylinder Hone Selection And Honing Procedure
        Honing To Deglaze
        Cleaning the Cylinder After Honing
        Oil Flow Chart
        Engine Lubrication Specifications
        OIL PRESSURE TEST
    ENGINE DISASSEMBLY AND INSPECTION
        Cylinder Head Assembly Exploded View
        Rocker Arms
        Push Rods
        Cylinder Head Removal 
        Cylinder Head Inspection
        Cylinder Head Warp
        Valve Seal/Spring Service (On Engine)
        Cylinder Head Disassembly
        Valve Inspection
        Combustion Chamber
        Valve Seat Reconditioning
        Cylinder Head Reassembly
        Valve Sealing Test
        Cylinder Removal
        Valve Lifter Removal/Inspection
        Piston Removal
        Cylinder Inspection
        Piston-To-Cylinder Clearance
        Piston/rod Inspection
        Piston Ring Installed Gap
        Starter Drive/Bendix Removal Inspection 
        Flywheel / Stator Removal / Inspection
        Engine Crankcase Disassembly / Inspection
        Camshaft Inspection
    ENGINE REASSEMBLY
        CRANKCASE REASSEMBLY
        Flywheel / Stator Installation
        Cylinder Head Reassembly
    TROUBLESHOOTING
        Engine
        Cooling System
    800 EFI Exhaust System
        Dual Exhaust Layout
        
CH 4 - FUEL INJECTION
    GENERAL INFORMATION
        Special Tools
        Service Notes
        EFI System Exploded View
        EFI System Component Locations
        Fuel Tank Assembly
        Fuel Lines - Quick Connect
    ELECTRONIC FUEL INJECTION
        Principal Components
        EFI Operation Overview
        Initial Priming / Starting Procedure
    ELECTRONIC CONTROL UNIT (ECU)
        Operation Overview
        ECU Service
        ECU Replacement
    FUEL PUMP
        Operation Overview
        Fuel Pump Test
        Fuel Pump / Tank Assembly Replacement
    FUEL PRESSURE REGULATOR
        Operation Overview
        Fuel Pressure Regulator Test
        Fuel Pressure Regulator Replacement
    FUEL FILTER
        General Information
        Fuel Filter Service
        Fuel Filter Replacement
    FUEL INJECTORS
        Operation Overview
        Fuel Injector Service
        Fuel Injector Replacement
    CRANKSHAFT POSITION SENSOR (CPS)
        Operation Overview
        Crankshaft Position Sensor Test
        Crankshaft Position Sensor (CPS) Replacement
    TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
        Operation Overview
        Temperature and Barometric Air Pressure Sensor Test
        Temperature and Barometric Air Pressure Sensor Replacement
    THROTTLE POSITION SENSOR (TPS)
        Operation Overview
        Throttle Position Sensor Replacement
        Throttle Position Sensor Test
        Throttle Position Sensor Initialization
    ENGINE TEMPERATURE SENSOR
        Operation Overview
        Engine Temperature Sensor Test
        Engine Temperature Sensor Replacement
    TROUBLESHOOTING
        Diagnostics Using “Blink Codes”
        EFI Troubleshooting
        EFI CIRCUIT - Power On
        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
        Special Tools 
        Decal Replacement
        Plastic Insert Removal / Installation
    BODY
        Side Panel Removal
        Front Cover Removal / Installation
        Foot Well Removal / Installation
        X2-Touring Foot Well Removal / Installation
        Front Storage Removal
        Front Storage Installation
        Sportsman Rear Rack Removal / Installation
        Front Cab/Fender Removal/Installation
        Sportsman Rear Cab / Fender Removal / Installation
        X2 Rear Quarter Panel Removal / Installation
        Sportsman Rear Storage Removal / Installation
        Radiator Screen Removal
        Sportsman Body Assembly Exploded View
        X2- Touring Body Assembly Exploded View
        Touring Body/Rack Assembly Exploded View
        Body / Rack Exploded Views
        Touring Body/Seat Assembly Exploded View
        Headlight Pod Exploded View
    STEERING
        Handlebar Block Installation Procedure
        Steering / A-arm Exploded View
        A-Arm Replacement
        Ball Joint Replacement
        Steering Post Removal
        Steering Post Assembly
    SUSPENSION
        Front Strut Cartridge Replacement
        Strut Assembly
        Sportsman Rear Suspension Assembly
        X2- Touring Rear Suspension Exploded View
        X2 Torsion Bar Exploded View
    X2 CARGO BOX
        Exploded View
        Removal / Installation
    X2 SEAT assembly
        Exploded Views
        X2 Seat Operation - Configuring Cargo Box For Passenger Riding
        X2 Driver Seat Backrest Removal / Installation
        X2 Passenger Seat Backrest Removal / Installation
        
CH 6 - CLUTCH SYSTEM
    SPECIAL TOOLS AND SPECIFICATIONS
        Special Tools
        Component Fastener Torques
    PVT EXPLODED VIEWS
        PVT Sealing And Ducting Components
        Drive Clutch Exploded Views (EBS vs. Non-EBS)
        Driven Clutch Exploded Views
        Engine Braking System (EBS) Exploded View
    PVT SYSTEM
        PVT Operation Overview
        Drive Clutch Operation
        Driven Clutch Operation
        EBS Clutch Operation
        PVT Maintenance / Inspection
        Drive Clutch Spring
        Optional Shift Weights
        PVT Drying
        PVT Disassembly 
        PVT Installation
        Drive Belt Removal / Inspection
        DRIVE BELT INSTALLATION
        Clutch Alignment
        Clutch Offset
    EBS DRIVE CLUTCH SERVICE
        Drive Clutch Disassembly
        Spider Removal
        Button To Tower Clearance Inspection
        Shift Weight Inspection
        Drive Clutch Inspection
        Moveable Sheave Bushing Inspection
        Drive Clutch Bushing Service
        One-Way Clutch Inspection (Drive Clutch)
        Drive Clutch Reassembly
    EBS DRIVEN CLUTCH SERVICE
        Driven Clutch Disassembly 
        DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION
        EBS DRIVEN CLUTCH REASSEMBLY
    PVT TROUBLESHOOTING
        Overheating
        Problem, Cause and Remedy Chart
        
CH 7 - FINAL DRIVE
    SPECIFICATIONS
        Torque Table
        Special Tools
        Gearcase Fluid / Capacity
    FRONT HUB
        Disassembly
        Assembly
    FRONT DRIVE SHAFT (CV) SERVICE
        Removal
        Installation
        Inspection
        CV Joint/Boot Replacement
    PROP SHAFT - FRONT OR REAR
        Removal and Installation
    U-JOINT
        Disassembly
        Assembly
    DRIVE AXLE EXPLODED VIEWS
        Drive Shafts and Propshafts
    FRONT GEARCASE - CENTRALIZED HILLIARD W/ Active descent control
        Operation
        ADC Gearcase Exploded View
        ADC Operation
        Front Gearcase Diagnosis
        Gearcase Removal
        Gearcase Installation
        Coil Testing
        ADC Differential Hydraulic Circuit Bleeding
        Disassembly / Inspection
        ADC Gearcase Piston Replacement Procedure
        Assembly
        Setting Ring Gear Backlash
    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
        Disassembly and Inspection
        Reassembly
        Installation 
        Rear Gearcase Exploded View
    sPORTSMAN 8.3-8.18
    sPORTSMAN X2 8.19-8.38
    
CH 8 - TRANSMISSION / SPORTSMAN
    TRANSMISSION EXPLODED VIEW
        Sportsman Transmission 
    SPECIFICIATONS
        Torque Specifications
        Lubricant / Capacity
    TRANSMISSION SERVICE
        Transmission Removal
        Disassembly
        Assembly
        Transmission Installation
        Troubleshooting
        
CH 8 - TRANSMISSION / X2 AND TOURING
    TRANSMISSION EXPLODED VIEWS
        Transmission Exploded View
        Mounting Exploded View
    SPECIFICATIONS
        Torque Specifications
        Special Tools
        Lubrication
    TRANSMISSION SERVICE
        Gear Selector Removal
        Transmission Removal
        Transmission Installation
        Troubleshooting Checklist
        Transmission Disassembly
        Transmission assembly
        Transmission front output shaft backlash procedure
        
CH 9 - BRAKES
    SPECIFICATIONS
        Torque Table
        Component Service Limits
    BRAKE SYSTEM Exploded Views
        X2, Touring System Component Exploded View
        Sportsman System Component Exploded View
    BRAKE CALIPER EXPLODED VIEWS
        Sportsman and X2, Touring Front Caliper Assembly
        X2, Touring Rear Caliper Assembly
        Sportsman Rear Caliper Assembly
    HYDRAULIC BRAKE SYSTEM
        Operation Overview
        Brake Noise Troubleshooting
        Brake Bleeding / Fluid Change
    FRONT MASTER CYLINDER
        Removal
        Installation
    FRONT BRAKES
        Pad Removal
        Assembly
        Brake Burnishing Procedure
    FRONT BRAKE DISC
        Inspection
        Removal / Replacement
    FRONT CALIPER
        Removal
        Inspection
        Reassembly
        Installation
    REAR BRAKE PAD
        X2, Touring Pad Removal
        X2, Touring Pad Installation
        Sportsman Rear Pad Removal
        Sportsman Rear Pad Installation
        Brake Burnishing Procedure
    X2, TOURING REAR CALIPER
        Removal
        Inspection
        Reassembly
    Sportsman REAR CALIPER
        Removal and Inspection
        Assembly
    REAR BRAKE DISC
        Inspection
    REAR MASTER CYLINDER
        X2, Touring Exploded View
        Overview
        X2, Touring Rear Master Cylinder Removal and Installation
        Sportsman Rear Master Cylinder Removal / Installation
        Pedal Removal and Installation
    TROUBLESHOOTING
        Brakes Squeal
        Poor Brake Performance
        Lever Vibration
        Caliper Overheats (Brakes Drag)
        Brakes Lock
        
CH 10 - ELECTRICAL
    INSTRUMENT CLUSTER 
        Overview
        Instrument Cluster Diagnostic Mode
        Setting A New Service Interval
        EFI Diagnostic Mode
        Speedometer Removal
        Speedometer Installation
    SPEEDOMETER TROUBLESHOOTING
        Test 1 - No All Wheel Drive
        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
        Operation Overview
        Diagnosing System Failures
    ALL WHEEL DRIVE (AWD) COIL
        Operation Overview
        Diagnosing System Failures
    COOLING SYSTEM COMPONENTS
        Fan Control Circuit Operation / Testing
        Fan Control Circuit Bypass Test
        Coolant Temperature Sensor
        Fan Motor Current Draw
    GEAR POSITION INDICATOR SWITCH
        Test Diagram
    ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
        ETC Switch Operation
        ETC Operation Test
    IGNITION SYSTEM
        Flywheel Identification
        EFI - DC/CDI Ignition Overview
        Alternator/Ignition Components - 700/800 EFI
        Crankshaft Position Sensor Gap
        Ignition System Troubleshooting
    CHARGING SYSTEM
        Current Draw - Key Off
        Charging System “Break Even” Test
        Alternator Output Test
        Charging System Testing Flow Chart
    RELAYS
        Operation
    FUSES/Circuit Breaker
        Operation
    LIGHTING
        High Beam Headlight Bulb Replacement
        Headlight Housing Replacement
        High Beam Headlight Adjustment 
        Lower Headlamp Removal / Installation
        Low Beam Headlight Adjustment
        Headlamp Switch Test
        Work Light / Differential Switch
        Sportsman / Touring Brake Light / Work Light Replacement
        X2 BRAKE LIGHT / WORK LIGHT REPLACEMENT
        Brake Light Switch
    FUEL SENDER
        Testing
    X2 / Touring DIFFERENTIAL System
        Solenoid Testing
        Solenoid Replacement
        Differential Relay Operation
        Differential Relay Testing
    X2 / TOURING SPEED SENSOR
        Testing
        Replacement
    ACCESSORY POWER
        Wire Connections
    STARTER SYSTEM
        Sportsman Starter Lockout Overview and Diagnostic
        X2 /TOURING Starter Lockout Overview and Diagnostic
        Troubleshooting
        Voltage Drop Test
        Starter Motor Removal / Disassembly 
        BRUSH INSPECTION / REPLACEMENT
        Armature Testing
        Starter Reassembly / Installation
        Starter Solenoid Bench Test
        Starter Drive
        Starter 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
    BASIC WINCH WIRING- PRE-WIRED MODELS
    BATTERY
        Battery Identification
        Battery Activation (Conventional)
        Battery Terminals/Bolts
        Conventional Battery Inspection / Removal
        Conventional Battery Installation
        Conventional Battery Testing
        Conventional Battery OCV - Open Circuit Voltage Test
        Conventional Battery Specific Gravity Test
        Battery Load Test
        Off Season Storage
        Charging Procedure
        Low Maintenance Battery
        Low Maintenance Battery Charging
        Low Maintenance Battery Inspection / Removal
        Low Maintenance Battery Installation
        Low Maintenance Battery - OCV- Open Circuit Voltage Test
        Low Maintenance Battery Load Test
        Low Maintenance Battery Off-season Storage
        Low Maintenance Battery Charging Procedure
    TROUBLESHOOTING DIAGRAMS
        Overview
        All Wheel Drive - EFI
        Charging Circuit - EFI
        Cooling Fan - EFI
        Fuel Pump - EFI
        Gear Switch - EFI
        Power Circuit - EFI
        Reverse Override - EFI
        Fan Control - EFI
        Start Circuit - EFI
        Start Enable - EFI
        
CH 11 - INTERNATIONAL TOURING
    800 TOURING EFI International BRAKE SYSTEM
        Overview
        Exploded View
    800 TOURING EFI International Steering Post and lock Assembly
        Steering Assembly Exploded View
    800 TOURING EFI INTERNATIONAL ELECTRICAL
        Turn / Hazard Signal Diagram
        
INDEX
WIRE DIAGRAMS

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