2008 Polaris Sportsman 800 EFI / Sportsman X2 700 EFI / Sportsman Touring 800 EFI Service Manual (P/N 9917722)

• 2008 service coverage: Applies to Sportsman 800 EFI A08MN76AF/AL/AQ/AS/AX, Sportsman X2 700 EFI A08TN68AZ/AX, and Sportsman Touring 800 EFI domestic A08DN76AF/AG/AH/AL/AS and International A08DN76FC/FH configurations. Engine coverage is split between EH076OLE for the 800 models and EH068OLE for the X2 700.
• Engine repair procedures: Covers engine removal and installation, crankcase disassembly and reassembly, cylinder-head and valve service, piston and cylinder inspection, honing, camshaft inspection, oil-pressure testing, cooling-system pressure testing, and the four-stroke coolant air-bleeding procedure.
• Bosch EFI diagnostics: Details fuel-pump and regulator testing, injector and sensor service, blink-code fault diagnosis, circuit checks, and throttle-position-sensor initialization. Listed equipment includes the PU-43506 fuel-pressure kit with PU-47476 test valve, PU-47082 TPS harness, and PU-47471 Digital Wrench SmartLink kit.
• PVT, transmission, and final drive: Provides EBS drive- and driven-clutch inspection and repair, clutch alignment and offset checks, separate Sportsman and X2/Touring transmission overhauls, front-output-shaft backlash setup, CV-joint and boot service, and Centralized Hilliard Active Descent Control gearcase diagnosis, bleeding, piston replacement, and ring-gear backlash adjustment.
• Chassis, brake, and electrical work: Documents body and rack removal, steering and A-arm repair, strut service, X2 cargo-box and seat assemblies, hydraulic-brake bleeding and caliper service, instrument-cluster diagnostics, charging and starter tests, plus model-specific electrical troubleshooting.
• 444 PDF pages total: 378-page 2008 service manual plus a separate 66-page 2005 Sportsman 800 EFI parts manual, P/N 9917721 (microfiche P/N 9917722), for A05MH76AC/AU/AW.

This factory PDF set centers on a model-specific 2008 service manual and adds a separate illustrated parts catalog for earlier Sportsman 800 EFI component identification. Its overhaul depth is suited to experienced technicians and advanced owners with the required measuring and service equipment; Polaris specifically reserves PVT repair for trained, certified Master Service Dealer technicians, while Digital Wrench diagnostics depend on dealer-only software and interface hardware.

Model-Specific Workshop Depth

The engine chapter distinguishes the EH068OLE and EH076OLE builds and identifies which components can be serviced in the chassis and which require engine removal. Supporting data covers fastener torque patterns, component-specific torque tables, inspection limits, clearances, lubrication requirements, oil-flow routing, cooling-system specifications, and pressure-test values. The transmission material is likewise divided by chassis: the regular Sportsman unit has its own exploded view and overhaul sequence, while the X2/Touring design receives separate removal, teardown, assembly, troubleshooting, and backlash-setting coverage.

X2 and Touring differences continue through the rear suspension, torsion bar, bodywork, passenger-seat hardware, rear braking, differential solenoid, and speed-sensor systems. A dedicated International chapter shows the Touring model's integrated four-wheel hydraulic brake arrangement, steering-post lock assembly, and turn/hazard-signal circuit.

Diagnostics, Diagrams, and Service Tools

Electrical diagnosis extends beyond wire colors and connector locations. The manual covers instrument-cluster and EFI diagnostic modes, eight numbered speedometer fault tests, ADC and AWD coil checks, cooling-fan control, gear-position and electronic-throttle-control switches, ignition and charging tests, starter-motor overhaul, and circuit-specific troubleshooting diagrams.

Named visual references include the Oil/Water Pump and Timing Cover exploded view, EFI System exploded view, EBS-versus-non-EBS Drive Clutch views, ADC Gearcase exploded view, and Charging System Testing Flow Chart. Full wiring diagrams are supplied for the Sportsman 800 EFI, 700 X2/800 Touring EFI, 800 Touring EFI International, and Sportsman ADC circuits. Other procedure-specific tools include the 2872292 EBS clutch alignment tool, PA-48542 ADC piston installation tool, and 2871695 X2/Touring transmission backlash tool.

Two cautions show why the factory procedure matters. The EFI section warns that disconnecting the ECU or component harnesses with the ignition on can send a damaging voltage spike through the ECU. The PVT chapter treats the clutch as a precision-balanced assembly and cautions against installing used parts from another clutch.

Included Parts Catalog and Scope

The 66-page parts manual is an October 2004 publication for the 2005 Sportsman 800 EFI A05MH76AC, A05MH76AU, and A05MH76AW. It supplies illustrated component breakdowns and itemized replacement-part tables for the body, brakes, driveline, clutches, gearcases, electrical assemblies, and engine. Polaris expressly states that these illustrations are for replacement-parts reference and are not to be used for assembly; use the 2008 service manual for repair procedures.

The 2008 service manual's publications table separately references Owner's Manual P/N 9921169 or 9921356 and 2008 Parts Manual P/Ns 9921349, 9921357, and 9921359. Those numbers identify related publications, not the included service-manual PDF. Because the set covers a pressurized EFI fuel system, hydraulic brakes, and rotating PVT components, follow the manual's safety warnings and specified service procedures before disassembly.