2007 Polaris Sportsman 700 EFI / Sportsman 800 EFI Service Manual (P/N 9920378, 9920374)

• Covers the 2007 Polaris Sportsman 700 EFI, 800 EFI, and 800 X2 EFI in a 536-page PDF set: a 393-page Service Manual (P/N 9920378) and a 143-page Owner’s Manual (P/N 9920374).
• Engine repair covers removal, cylinder-head overhaul, valve-seat reconditioning, crankcase disassembly, and camshaft/counterbalance gear timing.
• EFI diagnosis includes fuel-pressure and injector tests, TPS initialization, and blink-code/SAE fault-code reference charts.
• Separate non-EBS and Engine Braking System (EBS) PVT clutch procedures cover drive/driven clutch service, belt inspection, alignment, and offset adjustment.
• Front gearcase sections address Centralized Hilliard teardown and ring-gear backlash, plus Active Descent Control (ADC) inspection, piston replacement, and hydraulic bleeding.
• Transmission repair is split between the conventional 700/800 and X2, with geartrain reassembly, X2 differential service, and X2 front-output backlash adjustment.
• Chassis procedures cover brake-caliper rebuilding, hydraulic bleeding, front-strut and ball-joint replacement, and CV-joint/axle-boot service.

Model Coverage and Equipment Differences

The workshop coverage distinguishes the 700 Standard, 800 Standard/Deluxe, and 800 X2 Standard/Deluxe configurations. Both X2 trims use EBS; ADC front drive is Deluxe equipment. The 800 EFI International, model A07MH76FA, has dedicated coverage for its all-wheel brake system, steering-post lock, and turn/hazard signals.

The included owner’s manual covers 700/800 operation, break-in, cargo handling, and storage. X2 coverage is in the service manual, not the bundled owner’s book.

Engine Repair and EFI Diagnosis

The liquid-cooled twin-cylinder engine chapter separates in-frame work from jobs requiring engine removal. Internal service includes hydraulic-lifter inspection, piston/cylinder checks, crankshaft-bearing service, and post-rebuild oil priming. The Oil Flow Chart traces lubrication through the bearings and lifters.

Special-tool references include Cam Gear Tooth Alignment Tool PU-45497-2 and Oil System Priming Tool PU-45778. The water-pump seal section flags shaft damage from attempting seal replacement with the gear/stator housing still attached to the engine. The rebuild instructions also warn of internal engine damage at startup when oil priming is omitted.

Bosch MSE 1.1B system coverage addresses no-start, poor idle, lean/rich running, and crank-position or coolant-temperature sensor faults. The combined intake-air-temperature/barometric-pressure (T-BAP) sensor test calls for dealer-only Polaris diagnostic software and refers to the separate EFI Diagnostic Software Manual. Fuel-pump procedures cover testing and pump/tank assembly replacement, not internal pump overhaul.

Vehicle Maintenance and Specifications

Maintenance schedules distinguish normal and severe use, with chassis adjustments, engine oil service, cooling system upkeep, and transmission fluid replacement. Air-intake and brake-hydraulic checks, steering toe alignment, and suspension adjustments are also covered.

For X2 body repair, the manual documents cargo-box removal and convertible-seat/backrest service. Driveline work extends to propeller-shaft U-joints and the conventional models’ rear gearcase. The ADC Gearcase Exploded View identifies the pump, reservoir, piston, and clutch components within the Deluxe front-drive system.

Electrical Testing and Wiring Diagrams

Instrument cluster programming and diagnostic mode are accompanied by tests for all-wheel drive (AWD) engagement, fuel-gauge and gear indication, and the X2 Turf Mode differential solenoid. Charging-system work covers electrical-load/break-even testing, key-off current draw, and stator output. Starting-system sections address interlocks, voltage-drop testing, and starter-motor repair.

Wiring diagrams cover the conventional 700/800, 800 X2, and 800 EFI International harnesses. More focused references include the EFI Circuit – Throttle Position Sensor, Charging System Testing Flow Chart, and Turn / Hazard Signal Diagram for tracing component and circuit faults.

Technical Reference and Fluid Data

The reference data separate standard demand-drive lubrication from ADC hydraulic fluid and distinguish conventional from X2 transmission capacities. Cooling-system information covers antifreeze mixtures and pressure-cap standards. Component-specific torque tables, wear limits, clearances, electrical test values, and tire-pressure references support the related service procedures. The manual provides identification details for vehicle/frame VINs, engine serial numbers, and transmission numbers.

While this overview highlights the manuals’ contents, qualified mechanics should always rely on the complete OEM documentation prior to performing hands-on maintenance or diagnostic work, particularly on pressurized EFI fuel and hydraulic brake systems.