Category:
All-Terrain Vehicle (ATV)
Target User:
Recreational riders, utility users, outdoor enthusiasts, professional mechanics.
Competitors 2008:
Can-Am Outlander, Arctic Cat 700/1000, Yamaha Grizzly, Suzuki King Quad.
Unique Selling Points:
Versatile X2 design with convertible passenger/cargo mode, powerful V-twin engines, Polaris on-demand AWD system, comfortable ride.
Manual Value Proposition:
Provides essential knowledge for owners and technicians to maintain, diagnose, and repair their Polaris Sportsman, ensuring longevity and optimal performance.
Engine:
Detailed diagnostics, disassembly, assembly, torque specifications, timing, cooling system, lubrication system, fuel delivery, ignition system, emissions control.
Transmission:
CVT (Continuously Variable Transmission) inspection, service, belt replacement, clutch assembly, gearbox maintenance, differential service.
Drivetrain:
All-wheel drive (AWD) system, front and rear driveshafts, CV joints, gearcases, prop shafts, U-joints, maintenance and repair procedures.
Brakes:
Hydraulic brake system, front and rear calipers, master cylinder, brake lines, bleeding procedures, parking brake adjustment, component replacement.
Electrical:
Wiring diagrams, starter motor, alternator, battery, ignition system, lighting, instrumentation, charging system, EFI control module, fault diagnosis.
Suspension:
Front and rear suspension components, shocks, struts, control arms, bushings, wheel alignment, bearing service, adjustment procedures.
Steering:
Steering column, tie rods, steering rack, power steering system (if equipped), adjustments, maintenance.
Fuel System:
Fuel pump, fuel filter, fuel injectors, throttle body, fuel pressure regulator, EFI system troubleshooting.
Cooling System:
Radiator, fan, coolant hoses, water pump, thermostat, flush and fill procedures, temperature sensor diagnostics.
Bodywork And Chassis:
Frame inspection, body panel removal/installation, seat adjustment, storage compartment access, accessory mounting.
Accessories And Features:
Dump box operation (X2), tilt bed operation, lighting systems, electrical accessory hookups.
Maintenance:
Routine oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake system checks, tire pressure, battery maintenance, drive belt inspection.
Troubleshooting:
Systematic diagnostic procedures for engine performance issues, electrical faults, starting problems, driveability concerns, common failures.
Repair:
Step-by-step instructions for component replacement, rebuilds, and adjustments across all covered systems.
Diagnostics:
Diagnostic Trouble Codes (DTCs) interpretation for EFI system, electrical system troubleshooting guides, flow charts.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Depth Level:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed electrical system diagnostics and wiring diagrams.
Engine Type 700:
700cc V-twin, 4-stroke, SOHC, liquid-cooled
Engine Type 800:
800cc V-twin, 4-stroke, SOHC, liquid-cooled
Bore X Stroke 700:
Approx. 79.0 mm x 67.2 mm
Bore X Stroke 800:
Approx. 83.0 mm x 70.0 mm
Compression Ratio 700:
Approx. 9.5:1
Compression Ratio 800:
Approx. 9.5:1
Ignition:
Electronic Ignition
Horsepower 700:
Approx. 50 HP
Horsepower 800:
Approx. 55 HP
Torque 700:
Approx. 44 lb-ft
Torque 800:
Approx. 48 lb-ft
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane minimum)
Engine Oil Capacity:
Approx. 2.25 Quarts (2.1 Liters) with filter change
Engine Oil Type:
SAE 10W-40, API SG or higher (Polaris recommends specific ester-based synthetic blend)
Coolant Type:
Ethylene Glycol based antifreeze/coolant (Polaris recommended type or equivalent)
Oil Change Interval:
Every 100 hours or annually, whichever comes first.
Air Filter Service:
Clean every 50 hours; replace as needed.
Spark Plug Replacement:
Every 100 hours or annually.
Cv Belt Inspection:
Every 50 hours; replace at manufacturer's recommended mileage/hours or when worn.
Valve Adjustment:
Refer to manual for specific intervals, typically every 100-200 hours.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type Front Rear:
Polaris Demand Drive Fluid or equivalent SAE 80W-90 GL-5 gear oil (check manual for specifics).
Common Wear Items:
CV Axle boots, drive belts, ball joints, wheel bearings, brake pads, sway bar links (depending on usage).
Efi Related Concerns:
Occasional throttle body cleaning or sensor issues can arise with high usage.
Electrical System Quirks:
Corrosion on connectors can sometimes cause intermittent issues, especially in wet environments.