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

Polaris factory service manual for the 2007 Sportsman 700 EFI Standard, Sportsman 800 EFI Standard, Deluxe and International, and Sportsman X2 800 EFI Standard and Deluxe. P/N 9920378, copyright 2006, covers the EH068OLE and EH076OLE twin-cylinder engine families.

PDF Text Search, Bookmarks and Wiring Detail

Search and diagram access: The service text is searchable, with embedded bookmarks for chapters and individual procedures. Some diagnostic charts and the labels within the final wiring diagrams are not text-searchable. Small wiring labels and connection tables require zooming; the sideways drawings also benefit from page rotation.

One printable PDF contains 393 pages, including three introductory pages, eight notes pages and one otherwise blank index page. The five-page alphabetical index and seven wiring-diagram pages are also included in that total.

EFI Diagnosis and EBS/ADC Drivetrain Repair

These selected workshop topics are not a complete table of contents. Further coverage includes winch operation and ATV cleaning and storage.

• Engine and cooling: Engine removal and installation, cylinder-head and valve service, piston/cylinder inspection, crankcase overhaul, cam-gear timing, cooling-system pressure testing and bleeding, and oil-pressure diagnosis.

• EFI diagnosis: Fuel-pump and regulator tests, injector and sensor service, TPS testing and initialization, ECU replacement, and blink-code troubleshooting.

• PVT clutch service: Separate non-EBS and EBS procedures, drive and driven clutch disassembly, belt inspection, clutch alignment, offset adjustment, and troubleshooting.

• Transmission overhaul: Separate Sportsman and X2 removal, teardown and reassembly procedures, internal inspection, shift mechanisms, and X2 front-output backlash setup.

• Final-drive repair: Axle, CV-joint, boot and U-joint service, Standard Hilliard and Deluxe ADC gearcase overhaul, and ADC hydraulic bleeding and piston replacement.

• Brakes and chassis: Brake bleeding and component repair, steering and suspension service, body-panel removal, and X2 cargo-box and passenger-seat assemblies.

• Electrical troubleshooting: Instrument-cluster diagnostics, AWD/ADC and fan-circuit tests, ignition and charging checks, starter fault isolation, and model-specific wiring diagrams.

Polaris wrote this manual primarily for certified Master Service Dealer technicians in a properly equipped shop; it assumes knowledge of mechanical theory, tools and shop procedures.

Standard, Deluxe and International Configurations

The variant comparisons help match repair procedures, test circuits and parts configurations to the hardware fitted to the ATV.

Standard 700/800 Sportsman models use non-EBS PVT clutches and a centralized Hilliard front gearcase. The Deluxe 800 adds EBS, Active Descent Control, ADC-specific wiring and ECU hardware, and dual exhaust. Both X2 versions use EBS; ADC is limited to the Deluxe X2.

The International chapter explains its all-wheel hydraulic braking arrangement and includes steering-post lock assemblies and the turn/hazard signal circuit. Common service work is handled in the main system chapters.

Internal Engine Repair, Cooling and Lubrication

The engine chapter distinguishes components accessible with the engine installed from lower-end work requiring removal. Step-by-step procedures cover cylinder-head disassembly, valve-seat reconditioning, piston and ring inspection, crankcase separation and reassembly, crankshaft and counterbalance service, oil/water-pump repair, and flywheel/stator work.

Cylinder and valve limits: Nicasil-lined cylinders have deglazing coverage; excessive wear or damage calls for cylinder replacement. Valve-seat reconditioning is described, while the valve guides are not replaceable.

Cooling and lubrication diagnosis includes coolant-air bleeding, oil-flow tracing and oil-pressure testing. The Oil Flow Chart and Engine Fastener Torque Patterns accompany the inspection limits, sealant notes and tightening data.

Reassembly cautions: The manual specifies dry installation of the water-pump mechanical seal because lubrication can prevent proper sealing. It also documents post-rebuild oil-system priming with PU-45778, warning that an unprimed engine can suffer internal damage at initial startup.

EFI Tests and Dealer Diagnostic Tools

The EFI System Exploded View identifies the pump/tank assembly, pressure regulator, filters, injectors, ECU, crankshaft-position sensor, T-BAP sensor, TPS and engine-temperature sensor. Component tests are supported by blink-code diagnosis and circuit diagrams.

Diagnostic equipment: Polaris Digital Wrench PU-47063 is identified as dealer-only software. The manual lists the PU-43506 fuel-pressure test kit and dedicated TPS tools; T-BAP testing is directed to Digital Wrench and the separate EFI Diagnostic Software Manual.

Replacement scope: The fuel pump and pressure regulator are non-serviceable; replacement is at pump/tank assembly level. TPS replacement or repositioning requires the documented initialization procedure.

The fuel-system safety notes address retained EFI pressure and fire hazards during service.

Clutches, Gearcases and Transmission Setup

Clutch repair extends to one-way clutch inspection and bushing replacement. Clutching tables and the PVT Sealing and Ducting Components view support the separate non-EBS and EBS procedures.

Alignment and balance: The manual identifies the 2872292 clutch alignment tool for alignment and offset checks. Mixing used clutch parts or changing the original spider washer stack can upset clutch balance and belt clearance.

Front and rear hub, axle and propshaft work is covered alongside CV boots and U-joints. Gearcase procedures distinguish the Standard Hilliard unit from the ADC assembly, including ADC hydraulic-circuit bleeding and piston replacement with PA-48542.

Sportsman versus X2: The transmission chapters include gear and bearing inspection, shift components, case assembly and installation. X2 coverage adds differential-solenoid components and front-output backlash adjustment, with 2871695 listed as the backlash-setting tool.

The Sportsman chapter notes that its transmission illustrations depict a park lock that was removed for 2007.

Bodywork, Suspension and Brake Components

Chassis procedures cover cab and rack removal, A-arms, ball joints, steering-post assemblies, front strut cartridges and rear suspension. X2-specific material includes the torsion bar, cargo box, passenger-seat assemblies and backrests.

Brake coverage extends from pad and disc inspection to caliper and master-cylinder repair, fluid changes, burnishing, auxiliary brake service and fault diagnosis. Separate Sportsman and X2 component illustrations show the different arrangements.

Electrical Fault Finding and Wiring References

Electrical tests address the instrument cluster and speedometer, AWD and ADC coils, cooling-fan controls, ignition, charging, voltage drop and starter overhaul. Battery testing, lighting, X2 differential controls, accessory power and basic winch wiring are also covered.

The Charging System Testing Flow Chart supports charging diagnosis. The final wiring section contains diagrams for ADC, 700/800 EFI, 800 X2 EFI and International machines.

International wiring reference: The wire-termination table immediately following the International schematic is labeled for the 800 X2 EFI.

Maintenance and Workshop Reference Tables

Periodic maintenance charts distinguish normal and severe use, with lubricant and fluid references for the covered systems. Component-specific torque tables, capacities, clearances, wear limits, pressure-test specifications, electrical test values and adjustment data accompany the relevant service sections.

Selected Cylinder-Head and Piston Inspection Data

For the EH068OLE and EH076OLE engines, the cylinder-head table lists a surface-warp limit of 0.00394 in. (0.1 mm).

The cylinder/piston table specifies cylinder-to-piston clearance of 0.0015 ± 0.00059 in. (0.040 ± 0.015 mm), alongside separate piston and wrist-pin data for the two engine families.