Target Audience:
DIY enthusiasts, independent repair shops, Polaris owners seeking comprehensive maintenance and repair information
Value Proposition:
Cost-effective alternative to dealership service, providing factory-level repair data for a fraction of the cost.
Accessibility:
Instant digital download eliminates wait times and shipping costs.
Ease Of Use:
Designed for various skill levels with clear, easy-to-follow instructions.
Content Source:
Based on official factory service manuals and expert-created content.
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission (PVT), Drivetrain (AWD, Differentials)
Chassis And Suspension:
Frame, Front Suspension (A-arms), Rear Suspension (IRS), Shocks, Steering System
Brakes And Wheels:
Hydraulic Disc Brakes (Front & Rear), Parking Brake, Wheel Hubs, Tires
Electrical And Ignition:
Battery, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Lighting System, EFI Control Module (ECU), Sensors, Wiring Diagrams
Body And Trim:
Body Panels, Fenders, Seat, Handlebars, Racks
Maintenance:
Scheduled Maintenance, Fluid Checks and Changes, Filter Replacements, Spark Plug Service, Lubrication
Troubleshooting:
Diagnostic Charts, Symptom-Based Troubleshooting, Error Code Interpretation (EFI)
Repair And Overhaul:
Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Replacement
Assembly And Disassembly:
Step-by-step instructions for disassembling and reassembling major components and sub-assemblies
Diagnostic Capabilities:
Advanced diagnostics for EFI system, sensor testing, component resistance and voltage checks
Rebuild Procedures:
Detailed specifications and procedures for complete engine and transmission rebuilds
Electrical Schematics:
Comprehensive and detailed wiring diagrams for all electrical systems
Torque Specifications:
Precise torque values for all critical fasteners and bolt connections
Alignment And Calibration:
Procedures for steering alignment and potential EFI system calibrations
Engine Type:
4-Stroke DOHC V-Twin
Bore X Stroke Mm:
83 x 64.2
Cooling System:
Liquid-Cooled
Engine Type:
4-Stroke SOHC V-Twin
Bore X Stroke Mm:
85 x 69
Cooling System:
Liquid-Cooled
Horsepower Hp:
Approx. 50
Horsepower Hp:
Approx. 55
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Engine Oil Type:
SAE 0W-40 Synthetic recommended for wide temperature range. SAE 10W-40 API SG or higher also acceptable.
Oil Capacity L:
Approx. 2.5 (with filter change)
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand AWD (All-Wheel Drive) with 2WD Option
Differential:
Sealed Desmodromic (s-D) front differential
Atv Classification:
Class I Utility ATV
Braking System:
Hydraulic disc brakes front and rear with dual-piston calipers, Sealed hydraulic rear brake system with integrated parking brake.
Lighting:
Dual 35W Halogen headlights, 30W Halogen taillight/brake light
Footwells:
Aggressive floorboard serrations for grip
Operator Safety:
Always wear a helmet and appropriate protective gear. Read manual before operation.
Instrument Cluster:
Digital LCD instrument cluster displaying speedometer, tachometer, odometer, trip meter, fuel level, AWD indicator, and diagnostic codes.
Efi System:
Electronic Fuel Injection provides optimized fuel delivery for improved performance, throttle response, and cold-weather starting.
Diagnostic Port:
Diagnostic port for reading EFI error codes, facilitating troubleshooting.
Initial Break In:
First 10 hours or 200 miles: change engine oil and filter, inspect drive belt, check all fasteners and fluid levels.
Regular Maintenance:
Engine oil and filter change: every 6 months or 100 hours. Air filter cleaning/replacement: every 12 months or 100 hours. Spark plug inspection/replacement: every 12 months or 100 hours. Inspect drive belt: every 6 months or 100 hours. Grease suspension and steering components: every 6 months or 100 hours.
Transmission Oil:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 hypoid gear oil)
Coolant Type:
Ethylene Glycol based antifreeze/coolant (50/50 mixture with distilled water)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Drive Belt Wear:
Premature drive belt wear can occur with aggressive riding or if belt is contaminated. Regular inspection and proper belt tension are crucial.
Efi System Sensitivity:
EFI system can be sensitive to fuel quality and electrical connections. Ensure clean fuel filter and proper battery voltage.
Suspension Bushings:
Wear on suspension bushings and ball joints is common with high mileage and off-road use. Regular lubrication and inspection are recommended.
Manufacturer Origin:
Polaris Industries Inc., founded in 1954, is an American manufacturer known for its pioneering work in snowmobiles and later, ATVs.
Sportsman Line:
The Sportsman line, introduced in the early 1990s, became a benchmark for comfort, independent rear suspension, and versatile utility performance. The 700 and 800 EFI models represented significant advancements in power and fuel management.
Manufacturing Location:
Spearfish, South Dakota, USA (typical for this era of Polaris ATVs)
