2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual (P/N 9920378)

• Coverage: 2007 Sportsman 700 EFI Standard models; Sportsman 800 EFI Standard, Deluxe, and International models; and Sportsman X2 800 EFI Standard and Deluxe models, with EH068OLE and EH076OLE engine coverage.
• Covers engine removal and installation, cylinder-head and valve service, piston/cylinder inspection, crankcase teardown and reassembly, cam-gear timing, cooling-system pressure testing and bleeding, oil-pressure diagnosis, and post-rebuild oil-system priming.
• Includes EFI theory and diagnosis, fuel-pump and pressure-regulator testing, injector and sensor service, TPS testing and initialization, blink-code troubleshooting, ECU replacement, and high-pressure fuel-system precautions.
• Separates non-EBS and EBS PVT service, clutch alignment and offset, drive-belt inspection, Sportsman and X2 transmission overhaul, X2 output-backlash setup, CV/U-joint repair, and Standard Hilliard versus Deluxe ADC front-gearcase procedures.
• Details brake bleeding and component repair, steering and suspension service, X2 cargo-box and passenger-seat assemblies, instrument-cluster diagnostics, AWD/ADC and fan-circuit testing, charging and starter fault isolation, and model-specific wiring diagrams.

Content and System Coverage

This 393-page PDF contains the Polaris factory service publication for the 2007 Sportsman 700/800/800 X2 EFI, P/N 9920378, copyright 2006. Coverage is specific: the 700 EFI section identifies A07MH68AX, A07MH68AY, and A07MH68AZ Standard models; the 800 EFI section covers A07MH76AX/AY/AZ Standard, A07MN76AQ/AF Deluxe, and A07MH76FA International machines; and the X2 section covers A07TH76AU Standard and A07TN76AF Deluxe models. The manual identifies the EH068OLE and EH076OLE twin-cylinder engine families and provides separate Sportsman and X2 transmission sections. Polaris wrote it primarily for certified Master Service Dealer technicians, so it assumes shop-level mechanical knowledge and the specified service tools.

The configuration differences matter before repair work begins. Standard 700/800 Sportsman models use a non-EBS PVT and centralized Hilliard front gearcase. The Deluxe 800 adds EBS, Active Descent Control, ADC-specific wiring and ECU hardware, and the dual-exhaust layout. Both X2 configurations use EBS, while ADC is limited to the Deluxe X2. The International chapter isolates its all-wheel hydraulic brake arrangement, steering-post lock assembly, and turn/hazard signal circuit; shared repair procedures remain in the main chapters.

Engine coverage extends through complete internal repair. The manual distinguishes components that can be serviced with the engine installed from lower-end work requiring removal, then covers cylinder-head disassembly, valve-seat reconditioning, piston and ring inspection, Nicasil-cylinder deglazing, crankshaft and counterbalance service, oil/water-pump repair, flywheel and stator work, timing-gear alignment, and crankcase reassembly. Cooling-system pressure testing, coolant-air bleeding, oil-flow diagnosis, oil-pressure testing, and engine troubleshooting are paired with inspection limits, sealant notes, torque tables, and tightening patterns.

Drivetrain repair is divided by the fitted hardware. The PVT chapter separates Standard non-EBS and Deluxe/X2 EBS clutches, with drive and driven clutch disassembly, one-way clutch inspection, bushing replacement, belt service, alignment, offset, and troubleshooting. Final-drive coverage includes axle, CV-joint, boot, and U-joint service; Standard and ADC front-gearcase diagnosis; gearcase overhaul; ADC hydraulic bleeding; and ADC piston replacement. Separate Sportsman and X2 transmission chapters cover removal, internal disassembly, gear and bearing inspection, shift and park mechanisms, and reassembly. The X2 section adds differential-solenoid components and output-shaft backlash setup.

Body, steering, suspension, and brake chapters cover cab and rack removal, A-arms, ball joints, steering-post service, front strut cartridges, rear suspension, and the X2 torsion bar, cargo box, and passenger-seat assemblies. Brake procedures include bleeding and fluid change, pad and disc inspection, caliper and master-cylinder repair, burnishing, auxiliary brake service, and troubleshooting.

Fuel and electrical diagnosis receive dedicated factory procedures. The EFI chapter covers the pump/tank assembly, pressure regulator, filters, injectors, ECU, crankshaft-position sensor, T-BAP sensor, TPS, and engine-temperature sensor, with blink-code fault finding and TPS initialization. It identifies Polaris Digital Wrench PU-47063 as dealer-only diagnostic software and lists the PU-43506 fuel-pressure test kit and dedicated TPS tools. Electrical coverage adds instrument-cluster diagnostic mode, speedometer tests, AWD and ADC coil diagnosis, fan-circuit testing, ignition and charging checks, voltage-drop testing, starter overhaul, battery testing, lighting, X2 differential controls, accessory power, and winch wiring.

Specifications and Reference Data

Reference data is organized around the repair work: periodic maintenance requirements, approved lubricants and fluids, component-specific torque data, capacities, clearances, wear limits, pressure-test specifications, electrical test values, clutching tables, and adjustment data. Special tools include the 2872292 clutch alignment tool, 2871695 X2 transmission backlash-setting tool, PA-48542 ADC gearcase piston tool, and PU-45778 oil-system priming tool.

Named visual references include the Oil Flow Chart, Engine Fastener Torque Patterns, EFI System Exploded View, PVT Sealing and Ducting Components, Charging System Testing Flow Chart, and model-specific wire diagrams for ADC, 700/800 EFI, 800 X2 EFI, and International machines.

Several cautions show why this is a dealer-level repair manual rather than a maintenance summary. Fuel-rail pressure must be relieved before opening the EFI system. The PVT assemblies are precision-balanced, so mixing used clutch parts or disturbing the original washer stack can affect balance and belt clearance. During engine repair, the water-pump mechanical seal is installed dry, and a rebuilt engine must be oil-primed before its first start to prevent seal or internal engine damage.