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

• Covers Standard, Deluxe, and International configurations of the 2007 Polaris Sportsman 700, 800, and 800 X2 EFI
• Official Polaris OEM publication (P/N 9920378, copyright 2006)
• Features 15 detailed exploded-view diagrams, 11 maintenance interval tables, and precise torque-sequence charts for engine and crankcase assembly
• This 393-page reference serves as the primary technical source for the EH068OLE and EH076OLE engine series launch build

Content and System Coverage

Designed specifically for master dealer technicians, this manual delivers deep dives into engine theory, fuel system diagnostics, and drivetrain service. You will find extensive chapters detailing cooling system pressure testing, cylinder head reassembly, and complete transmission maintenance. It maps out sub-assemblies with expert-level clarity, breaking down complex factory layouts with a heavy focus on lubrication paths, intricate electrical schematics, and suspension geometry to speed up diagnostic times in a busy shop. Working on these specific machines involves high-pressure EFI systems, so it is highly recommended to familiarize yourself with proper depressurization protocols before tackling any fuel delivery components to avoid injury.

Specifications and Reference Data

Having exact tolerances on hand eliminates guesswork during a rebuild. This publication clearly documents critical engine clearances, fluid capacities, and specific torque values for crankcase bolts. The engine data tables specify a 0.9 mm spark plug gap for the 700 EFI, while the periodic maintenance chart lists intake valve clearance checks at the 100-hour mark. For the 800 EFI, baseline cylinder compression is fully documented at 150–200 psi. Beyond the engine block, the manual thoroughly outlines reference values for ignition timing, electrical circuit breaker ratings, and factory suspension adjustments.