Polaris 2008 sportsman 800efi Manuals

Manuals and User Guides for Polaris 2008 sportsman 800efi. We have 1 Polaris 2008 sportsman 800efi manual available for free PDF download: Service Manual

Polaris 2008 sportsman 800efi Service Manual

Polaris 2008 sportsman 800efi Service Manual (388 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 58.59 MB

Table of Contents

General Information Chapter 1 1

5
- Table of Contents
  5
- Chapter 1
  6
- Engine and Machine Serial Numbers
  6
- Engine Designation Numbers
  6
- General Information
  6
- Model Information
  6
- Model Number
  6
- Transmission I.D. Location
  6
- Vin Identification
  6
- Paint Codes
  7
- Publications
  7
- Replacement Keys
  7
- 2008 Sportsman 800 Efi
  8
  - Model Number: A08Mn76Af, Al, Aq, As, Ax
    8
- 2008 Sportsman X2 700 Efi
  10
  - Model Number: A08Tn68Az, Ax
    10
- 2008 Sportsman Touring 800 Efi
  12
  - Model Number: A08Dn76Af, Ag, Ah, Al, Al, as / A08Dn76Fc, Fh
    12
- Misc. Numbers/Charts
  14
  - Standard Torque Specifications
    14
  - Special Tools
    14
  - Sae Tap Drill Sizes
    15
  - Metric Tap Drill Sizes
    15
  - General
    16
  - Conversion Table
    16
  - Glossary of Terms
    17
Maintenance Chapter 2 Maintenance 2

19
- Chapter 2
  21
- Maintenance
  21
- Maintenance Chart Key
  21
- Overview
  21
- Periodic Maintenance Chart
  22
- Lubrication / Fluids
  25
- Vehicle Inspection
  33
  - Shift Link Rod Inspection
    33
  - Throttle Inspection
    34
  - Throttle Cable / Electronic Throttle Control Adjustment
    34
  - Fuel System
    35
    
    Electrical
    35
  - Vent Lines
    35
  - Compression Test
    35
  - Engine Mounts
    36
  - Spark Plug
    36
  - Active Descent Control (Adc) Reservoir Level
    36
  - Battery Maintenance
    37
  - Cooling System
    37
  - Coolant Strength / Type
    38
  - Cooling Hoses
    38
  - Radiator
    38
  - Cooling System Pressure Test
    38
  - Reservoir Level Inspection
    38
  - Radiator Coolant Level
    39
  - Air Filter Service
    39
  - Air Box Sediment Tube
    40
  - Engine Breather Hose
    40
  - Pvt Inspection / Drying Procedure
    41
  - Engine Ground
    41
  - Engine Oil Level
    41
  - Oil/Filter Change
    42
  - Steering Inspection
    43
  - Tie Rod / Steering
    43
  - Camber/Caster
    43
  - Wheel Alignment
    44
  - Toe Alignment
    44
  - Exhaust Pipe
    45
  - Brake System Inspection
    45
  - Brake Pads
    46
  - Brake Hose Inspection
    46
  - Auxiliary (Rear) Brake Test
    46
  - Auxiliary Brake Adjustment
    47
  - Suspension: Spring Preload Adjustment
    47
  - Front Suspension
    47
  - Rear Suspension
    47
  - CV Shaft Boot Inspection
    47
- Atv Controls
  48
- Wheel Inspection
  48
- Wheel Installation
  48
- Wheel Removal: Front or Rear
  48
- Frame, Nuts, Bolts, Fasteners
  49
- Front / Rear Storage Compartments
  49
- Tire Inspection
  49
- Tire Pressure
  49
- Winch Operation (if Equipped)
  50
- Cleaning and Storage of Atv
  52
- Maintenance Schedule
  55
Chapter 3 Engine

57
- Crankcase Exploded Views
  58
- Specifications
  58
- Engine Fastener Torque Patterns
  65
- Torque Specifications
  66
- 700/800 Efi Engine Service Specifications
  67
- Special Tools
  69
- General Engine Service
  70
  - Accessible Components
    70
  - Piston Identification
    70
  - Cooling System Specifications
    70
  - Cooling System Pressure Test
    71
  - Four Stroke - Coolant Air Bleeding Procedure
    71
  - Engine Removal (Typical)
    72
    
    Clutch
    73
  - Engine Installation Notes
    74
  - Cylinder Hone Selection and Honing Procedure
    74
  - Honing to Deglaze
    75
  - Cleaning the Cylinder after Honing
    75
  - Oil Flow Chart
    76
  - Engine Lubrication Specifications
    76
  - Oil Pressure Test
    76
- Engine Disassembly and Inspection
  77
  - Cylinder Head Assembly Exploded View
    77
  - Rocker Arms
    78
  - Push Rods
    78
  - Cylinder Head Removal
    78
  - Cylinder Head Inspection
    79
  - Cylinder Head Warp
    79
  - Valve Seal/Spring Service (on Engine)
    79
  - Cylinder Head Disassembly
    80
  - Valve Inspection
    81
  - Combustion Chamber
    82
  - Valve Seat Reconditioning
    82
  - Cylinder Head Reassembly
    84
  - Valve Sealing Test
    85
  - Cylinder Removal
    85
  - Valve Lifter Removal/Inspection
    85
  - Piston Removal
    86
  - Cylinder Inspection
    87
  - Piston-To-Cylinder Clearance
    88
  - Piston/Rod Inspection
    88
  - Piston Ring Installed Gap
    89
  - Starter Drive/Bendix Removal Inspection
    89
  - Flywheel / Stator Removal / Inspection
    90
  - Engine Crankcase Disassembly / Inspection
    91
  - Camshaft Inspection
    98
- Engine Reassembly
  99
  - Crankcase Reassembly
    99
  - Flywheel / Stator Installation
    110
  - Cylinder Head Reassembly
    111
- Troubleshooting
  113
  - Engine
    113
  - Cooling System
    114
- 800 Efi Exhaust System
  115
  - Dual Exhaust Layout
    115
Fuel Injection Chapter 4 Fuel Injection

117
- Chapter 4
  118
- General Information
  118
- Special Tools
  118
- Service Notes
  120
- Efi System Exploded View
  121
- Efi System Component Locations
  122
- Fuel Lines - Quick Connect
  123
- Fuel Tank Assembly
  123
- Electronic Fuel Injection
  124
  - Principal Components
    124
  - Efi Operation Overview
    124
  - Initial Priming / Starting Procedure
    124
- Electronic Control Unit (Ecu)
  125
  - Operation Overview
    125
  - Ecu Service
    125
  - Ecu Replacement
    125
- Fuel Pump
  126
  - Operation Overview
    126
  - Fuel Pump Test
    126
  - Fuel Pump / Tank Assembly Replacement
    127
- Fuel Filter
  128
  - General Information
    128
  - Fuel Filter Service
    128
  - Fuel Filter Replacement
    128
- Fuel Pressure Regulator
  128
  - Operation Overview
    128
  - Fuel Pressure Regulator Test
    128
  - Fuel Pressure Regulator Replacement
    128
- Fuel Injectors
  129
  - Operation Overview
    129
  - Fuel Injector Service
    129
  - Fuel Injector Replacement
    129
- Crankshaft Position Sensor (Cps)
  130
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  131
- Throttle Position Sensor (Tps)
  131
- Engine Temperature Sensor
  134
  - Operation Overview
    134
  - Engine Temperature Sensor Test
    134
  - Engine Temperature Sensor Replacement
    134
- Diagnostics Using "Blink Codes
  135
- Troubleshooting
  135
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

141
- Chapter 5
  142
- Decal Replacement
  142
- General Information
  142
- Special Tools
  142
- Torque Specifications
  142
- Plastic Insert Removal / Installation
  143
- Body
  144
- Steering
  158
  - Handlebar Block Installation Procedure
    158
  - Steering / A-Arm Exploded View
    159
  - A-Arm Replacement
    160
  - Ball Joint Replacement
    161
  - Steering Post Removal
    162
  - Steering Post Assembly
    162
- Suspension
  162
  - Front Strut Cartridge Replacement
    162
  - Strut Assembly
    163
  - Sportsman Rear Suspension Assembly
    164
  - X2- Touring Rear Suspension Exploded View
    165
  - X2 Torsion Bar Exploded View
    166
- X2 Cargo Box
  167
  - Exploded View
    167
  - Removal / Installation
    168
- X2 Seat Assembly
  170
Clutch System Chapter 6 Clutch System

175
- Chapter 6
  176
- Component Fastener Torques
  176
- Special Tools
  176
- Special Tools and Specifications
  176
- Pvt Exploded Views
  177
- Pvt System
  180
  - Pvt Operation Overview
    180
  - Drive Clutch Operation
    180
  - Driven Clutch Operation
    180
  - Ebs Clutch Operation
    181
  - Pvt Maintenance / Inspection
    181
  - Drive Clutch Spring
    182
  - Optional Shift Weights
    183
  - Pvt Drying
    184
  - Pvt Disassembly
    184
  - Pvt Installation
    185
  - Drive Belt Removal / Inspection
    186
  - Drive Belt Installation
    187
  - Clutch Alignment
    188
  - Clutch Offset
    188
- Ebs Drive Clutch Service
  189
  - Drive Clutch Disassembly
    189
  - Spider Removal
    189
  - Button to Tower Clearance Inspection
    191
  - Shift Weight Inspection
    191
  - Drive Clutch Inspection
    191
  - Moveable Sheave Bushing Inspection
    192
  - Drive Clutch Bushing Service
    192
  - One-Way Clutch Inspection (Drive Clutch)
    194
  - Drive Clutch Reassembly
    194
- Ebs Driven Clutch Service
  196
- Pvt Troubleshooting
  203
  - Overheating
    203
  - Problem, Cause and Remedy Chart
    204
Final Drive Chapter 7 Final Drive

207
- Final Drive
  207
- Chapter 7
  208
- Front Hub
  208
  - Disassembly
    208
  - Assembly
    209
- Gearcase Fluid / Capacity
  208
- Special Tools
  208
- Specifications
  208
- Torque Table
  208
- Front Drive Shaft (CV) Service
  209
  - Removal
    209
  - Installation
    210
  - Inspection
    211
  - CV Joint/Boot Replacement
    211
- Prop Shaft - Front or Rear
  213
  - Removal and Installation
    213
- U-Joint
  213
  - Disassembly
    213
  - Assembly
    214
- Drive Axle Exploded Views
  216
  - Drive Shafts and Propshafts
    216
- Front Gearcase - Centralized Hilliard W/ Active Descent Control
  217
  - Operation
    217
  - Adc Gearcase Exploded View
    218
  - Adc Operation
    219
  - Front Gearcase Diagnosis
    220
  - Gearcase Removal
    221
  - Gearcase Installation
    222
  - Coil Testing
    223
  - Adc Differential Hydraulic Circuit Bleeding
    223
  - Disassembly / Inspection
    223
  - Adc Gearcase Piston Replacement Procedure
    227
  - Assembly
    229
  - Setting Ring Gear Backlash
    232
- Rear Hub
  233
  - Removal
    233
  - Disassembly
    234
  - Assembly
    235
  - Installation
    235
- Rear Drive (CV) Shaft
  236
  - Removal
    236
  - Service
    237
  - CV Boot Replacement
    238
  - Installation
    239
  - Drive Shaft and CV Joint Handling Tips
    239
- Rear Gearcase
  240
  - Removal
    240
  - Disassembly and Inspection
    240
  - Reassembly
    241
  - Installation
    242
  - Rear Gearcase Exploded View
    244
Sportsman Transmission Chapter 8 Sportsman Transmission

247
- Chapter 8 Sportsman Transmission
  248
- Transmission Exploded View
  248
- Specificiatons
  250
  - Torque Specifications
    250
  - Lubricant / Capacity
    250
- Transmission Service
  250
  - Transmission Removal
    250
  - Disassembly
    251
  - Assembly
    256
  - Transmission Installation
    261
  - Troubleshooting
    262
X2 / Touring Transmission Chapter 8 X2 / Touring Transmission

263
- Transmission Exploded Views
  264
  - Transmission Exploded View
    264
  - Mounting Exploded View
    266
- Specifications
  267
  - Torque Specifications
    267
  - Special Tools
    267
  - Lubrication
    267
- Transmission Service
  267
  - Gear Selector Removal
    267
  - Transmission Removal
    267
  - Transmission Installation
    269
  - Troubleshooting Checklist
    270
  - Transmission Disassembly
    271
  - Transmission Assembly
    276
  - Transmission Front Output Shaft Backlash Procedure
    277
Brakes Chapter 9 Brakes

283
- Chapter 9
  284
- Component Service Limits
  284
- Specifications
  284
- Torque Table
  284
- Brake System Exploded Views
  285
  - X2, Touring System Component Exploded View
    285
  - Sportsman System Component Exploded View
    286
- Brake Caliper Exploded Views
  287
- Hydraulic Brake System
  288
  - Operation Overview
    288
  - Brake Noise Troubleshooting
    289
  - Brake Bleeding / Fluid Change
    289
- Front Master Cylinder
  291
  - Removal
    291
  - Installation
    291
- Front Brakes
  292
  - Pad Removal
    292
  - Assembly
    293
  - Brake Burnishing Procedure
    294
- Front Brake Disc
  294
  - Inspection
    294
  - Removal / Replacement
    295
- Front Caliper
  296
  - Removal
    296
  - Inspection
    297
  - Reassembly
    297
  - Installation
    298
- Rear Brake Pad
  299
  - X2, Touring Pad Removal
    299
  - X2, Touring Pad Installation
    300
  - Sportsman Rear Pad Removal
    301
  - Sportsman Rear Pad Installation
    302
  - Brake Burnishing Procedure
    302
- X2, Touring Rear Caliper
  303
  - Removal
    303
  - Inspection
    304
  - Reassembly
    304
- Sportsman Rear Caliper
  305
  - Removal and Inspection
    305
  - Assembly
    306
- Rear Brake Disc
  307
  - Inspection
    307
- Rear Master Cylinder
  308
- Troubleshooting
  311
Chapter 10 Electrical

313
- Instrument Cluster
  315
- Overview
  315
- Instrument Cluster Diagnostic Mode
  316
- Setting a New Service Interval
  318
- Efi Diagnostic Mode
  319
- Speedometer Removal
  320
- Speedometer Installation
  321
- Speedometer Troubleshooting
  322
- Active Descent Control (Adc) Coil
  327
  - Operation Overview
    327
  - Diagnosing System Failures
    327
- All Wheel Drive (Awd) Coil
  327
- Cooling System Components
  328
  - Fan Control Circuit Operation / Testing
    328
  - Fan Control Circuit Bypass Test
    328
  - Coolant Temperature Sensor
    328
  - Fan Motor Current Draw
    329
- Gear Position Indicator Switch
  329
  - Test Diagram
    329
- Electronic Throttle Control (Etc) Switch
  330
  - Etc Switch Operation
    330
  - Etc Operation Test
    330
- Ignition System
  331
  - Flywheel Identification
    331
  - Efi - DC/CDI Ignition Overview
    331
  - Alternator/Ignition Components - 700/800 Efi
    332
  - Crankshaft Position Sensor Gap
    333
  - Ignition System Troubleshooting
    333
- Charging System
  333
  - Current Draw - Key off
    333
  - Charging System "Break Even" Test
    334
  - Alternator Output Test
    334
  - Charging System Testing Flow Chart
    336
- Relays
  337
  - Operation
    337
  - Power Relay
    337
- Fuses/Circuit Breaker
  338
  - Operation
    338
- Lighting
  338
  - High Beam Headlight Bulb Replacement
    338
  - Headlight Housing Replacement
    339
  - High Beam Headlight Adjustment
    340
  - Lower Headlamp Removal / Installation
    340
  - Low Beam Headlight Adjustment
    341
  - Headlamp Switch Test
    341
  - Work Light / Differential Switch
    342
  - Sportsman / Touring Brake Light / Work Light Replacement
    342
  - X2 Brake Light / Work Light Replacement
    343
  - Brake Light Switch
    344
  - Testing
    345
- Fuel Sender
  345
- X2 / Touring Differential System
  345
  - Solenoid Testing
    345
  - Solenoid Replacement
    345
  - Differential Relay Operation
    346
  - Differential Relay Testing
    346
- X2 / Touring Speed Sensor
  346
  - Testing
    346
  - Replacement
    346
- Accessory Power
  347
  - Wire Connections
    347
- Starter System
  348
  - Sportsman Starter Lockout Overview and Diagnostic
    348
  - X2 /Touring Starter Lockout Overview and Diagnostic
    349
  - Troubleshooting
    350
  - Voltage Drop Test
    350
  - Starter Motor Removal / Disassembly
    350
  - Brush Inspection / Replacement
    351
  - Armature Testing
    352
  - Starter Reassembly / Installation
    353
  - Starter Solenoid Bench Test
    353
  - Starter Drive
    354
  - Starter Exploded View
    355
- Starter System Testing Flow Chart
  356
- Basic Winch Wiring- Pre-Wired Models
  357
- Battery
  358
- Troubleshooting Diagrams
  366
  - Overview
    366
  - All Wheel Drive - Efi
    366
  - Charging Circuit - Efi
    366
  - Cooling Fan - Efi
    367
  - Fuel Pump - Efi
    367
  - Gear Switch - Efi
    368
  - Power Circuit - Efi
    368
  - Reverse Override - Efi
    369
  - Fan Control - Efi
    369
  - Start Circuit - Efi
    370
  - Start Enable - Efi
    370
  - International
    371
- 800 Touring Efi International Brake System
  372
- Chapter 11
  372
- Overview
  372
- Exploded View
  373
- 800 Touring Efi International Steering Post and Lock Assembly
  374
  - Steering Assembly Exploded View
    374
- 800 Touring Efi International Electrical
  375
  - Turn / Hazard Signal Diagram
    375

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