Positioning:
The Polaris Sportsman X2 series (700, 800 EFI, 800 Touring) represented a versatile, utility-focused ATV with a unique convertible passenger/cargo bed. This manual is targeted at owners who perform their own maintenance and repairs, seeking the same factory-level information used by authorized service centers.
Competitors:
Competed against other premium utility ATVs from brands like Can-Am (Outlander), Yamaha (Grizzly), and Honda (Foreman/Rancher), particularly in the 700-800cc class. The X2's unique feature was its adaptability for carrying both cargo and a passenger.
Manual Value Proposition:
Provides factory-direct accuracy, comprehensive coverage across multiple model variants for the year, detailed diagrams, and troubleshooting guides, offering significant cost savings and empowerment for DIY maintenance and repair.
Systems Covered:
Engine (all variants), Fuel System (EFI), Drivetrain (AWD/2WD), Suspension (Independent Front/Rear), Brakes (Hydraulic Disc), Electrical System, Frame, Bodywork, Chassis, Accessories, Troubleshooting, Maintenance.
Estimated Pages:
Likely 500+ pages based on typical factory service manuals for complex ATVs.
Type:
Factory Service / Repair / Maintenance Manual
Format:
PDF Download (55 MB)
Engine:
Detailed disassembly, assembly, inspection, and repair procedures for the Polaris 700cc and 800cc ProStar EFI engines, including top-end, bottom-end, cooling system, lubrication, and ignition components.
Fuel System:
Comprehensive coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, throttle body, sensors (MAP, TPS, IAT), fuel pressure regulator, and diagnostic procedures.
Drivetrain:
Service and repair of the all-wheel-drive (AWD) system (on-demand), clutch systems (primary and secondary), drive belts, gears, and differential components.
Suspension Steering:
Detailed information on independent front and rear suspension, shock absorbers, A-arms, bushings, steering linkage, tie rods, wheel bearings, and alignment procedures.
Brakes:
Front and rear hydraulic disc brake system service, including master cylinders, calipers, brake pads, brake lines, bleeding procedures, and rotor inspection.
Electrical:
Complete wiring diagrams, electrical component testing, battery, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition switch, and accessory wiring.
Body Chassis:
Frame inspection and repair, body panel removal/installation, seat, handlebars, racks, and the unique X2 convertible cargo bed/passenger seat system.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel), spark plug replacement, valve adjustments, belt inspection/replacement, and lubrication points.
Troubleshooting:
Systematic diagnostic flowcharts and symptom-based troubleshooting for common issues related to starting, running, electrical faults, and operational problems.
Repair:
Step-by-step repair procedures for virtually all components and systems, from minor adjustments to major overhauls and component replacement.
Diagnostics:
Guidance on using diagnostic tools (if applicable for EFI systems), interpreting error codes, and performing system checks.
Depth:
Comprehensive. Covers everything from basic fluid checks and filter changes to complete engine teardowns, transmission rebuilding, and advanced electrical system diagnostics. Equivalent to what a Polaris dealership technician would use.
Engine Type 700:
4-stroke, Liquid-Cooled, SOHC, V-Twin
Engine Type 800:
4-stroke, Liquid-Cooled, SOHC, V-Twin
Bore Stroke 700 Approx:
Approx. 83mm x 64mm
Bore Stroke 800 Approx:
Approx. 93mm x 73mm
Horsepower 700 Approx:
Approx. 50-55 HP
Horsepower 800 Approx:
Approx. 55-60 HP
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 octane recommended)
Cooling Method:
Liquid Cooling
Oil Type Specification:
Polaris Synthetic 0W-40 (or equivalent meeting API SM classification)
Oil Capacity With Filter:
Approx. 2.5 Liters (refer to manual for exact specs)
Type:
Automatic CVT (Continuously Variable Transmission) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand True All-Wheel Drive (AWD) with 2WD option
Clutch Fluid:
Polaris Synthetic CVT Fluid (or equivalent)
Clutch Fluid Capacity:
Refer to manual for specific transmission case capacity.
Length:
Approx. 85.5 inches (217.2 cm)
Width:
Approx. 48 inches (121.9 cm)
Height:
Approx. 47.4 inches (120.4 cm)
Dry Weight:
Approx. 670-690 lbs (304-313 kg) depending on exact model variant.
Gvw:
N/A (ATV classification)
Front Rack Capacity:
Approx. 100 lbs (45.4 kg)
Rear Rack Capacity X2:
Approx. 200 lbs (90.7 kg) in cargo mode.
Towing Capacity:
Approx. 1,500 lbs (680 kg)
Crash Test Ratings:
N/A (ATVs are not subject to the same automotive crash testing standards).
Braking System:
Hydraulic Disc Brakes (Front & Rear), Engine Braking
Lighting:
Dual 50W Halogen Headlights, Single 30W Tail/Brake Light
Operator Presence:
Handlebar controls with throttle limiter and safety interlocks.
Tire Type:
ATV specific tires for off-road traction and stability.
Infotainment System:
Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, clock, and indicator lights. No advanced infotainment features.
Driver Assistance:
On-Demand AWD system provides enhanced traction. No electronic driver aids like traction control or stability control.
Connectivity:
None. Focus is on mechanical and electrical systems.
Oil Change:
Every 100 hours or 6 months, whichever comes first.
Air Filter:
Inspect every 50 hours, clean/replace as needed. Replace every 100 hours or annually.
Spark Plug:
Replace every 100 hours or annually.
Drive Belt:
Inspect every 50 hours, replace at 100 hours or if damaged.
Engine Oil:
Polaris Synthetic 0W-40 (API SM or higher)
Coolant:
50/50 mixture of Polaris Premium Pre-Mix Coolant and distilled water (Ethylene Glycol based).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Common Problems:
Potential for drive belt wear or breakage under heavy load, occasional EFI sensor issues (TPS, MAP), and wear on suspension bushings over time due to off-road use. Some models may have experienced rear differential issues.
Oil Filter Example:
2445433 (Polaris OEM, verify for specific engine variant)
Heritage:
Polaris Industries is a long-standing American manufacturer known for snowmobiles, ATVs, and powersports vehicles. They have a reputation for innovation and performance in the off-road market.
Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving with more powerful engines, advanced suspension, and features like the EFI systems and the unique X2 convertible design introduced in preceding years.
Production Era:
Mid-to-late 2000s, with the 700 and 800cc engines being popular in this period.
