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Polaris ATV 2008 Sportsman 800 EFI X2 700 EFI Repair Manual

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This manual provides comprehensive repair and service information for the 2008 Sportsman 800 EFI X2, Sportsman X-2 700 EFI, and Sportsman Touring 800 EFI models. A renowned American manufacturer has a strong heritage in powersports, and the Sportsman line is celebrated for its comfort, utility, and off-road capability. The X2 variant notably features a versatile 2-up seating configuration. These ATVs are engineered for a wide range of terrains and tasks, offering robust performance and reliability. This factory service manual is the definitive resource for maintaining and repairing your 2008 Sportsman. It covers all essential systems, including detailed procedures for the engine, fuel system, transmission, drivetrain, suspension, steering, brakes, and electrical systems. You will find step-by-step instructions for scheduled maintenance, component repair, disassembly and reassembly, and troubleshooting. With factory-level accuracy and detail, this manual equips owners and technicians with the knowledge necessary to keep their vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI X2 Model Variant: Sportsman 800 EFI, Sportsman X-2 700 EFI, Sportsman Touring 800 EFI Year: 2008 Product Type: Repair Manual / Service Manual Codes Manual Identifier: Polaris Factory Service Manual 👋 Introduction Market Position Positioning: The definitive factory service resource for owners and technicians of the 2008 Polaris Sportsman 800 EFI X2, 700 EFI X2, and Touring 800 EFI models. Competitive Analysis Comparison: Outperforms aftermarket manuals in accuracy, completeness, and detail, providing factory-level information. Key Features Features: Original factory data, comprehensive system coverage, detailed diagrams, and troubleshooting guides. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair, service, and technical information for 2008 Polaris Sportsman models. Page Count Total Pages: 388 Manual Type Type: Factory Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul procedures for the 700cc and 800cc ProStar EFI engines. Fuel System: EFI system, fuel pump, injectors, throttle body, and fuel tank service. Cooling System: Radiator, fan, thermostat, coolant specifications, and flushing procedures. Transmission: PVT (Polaris Variable Transmission) system, belt inspection, replacement, clutch service, and drivetrain. Drivetrain: AWD system, front differential, rear differential, driveshafts, and U-joints. Suspension: Front and rear suspension systems, shock absorbers, springs, bushings, and alignment. Steering: Handlebars, tie rods, steering rack, and linkage service. Brakes: Hydraulic brake system, master cylinders, calipers, rotors, brake fluid specifications, and bleeding procedures. Electrical System: Battery, charging system (stator, voltage regulator), starter motor, ignition system, lighting, and wiring diagrams. Chassis And Body: Frame, body panels, fenders, seat, racks, and cargo box (X2 specific) disassembly and reassembly. Instruments And Controls: Gauges, switches, controls, and accessory power outlets. Troubleshooting: Extensive diagnostic flowcharts and troubleshooting guides for common and uncommon issues. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, valve adjustments, and drive belt inspection. Repair: Step-by-step instructions for component repair, replacement, and overhaul of all major systems. Diagnostics: Detailed diagnostic procedures, fault codes (DTCs), and testing methodologies. Assembly Disassembly: Complete guidance on dismantling and reassembling the entire ATV. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Detail Level: Includes torque specifications, clearances, tolerances, and detailed diagrams. Target Audience: Professional technicians, experienced DIY mechanics, and serious ATV enthusiasts. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (assuming standard PDF creation) Printable: Yes Print Quality Quality: Original Factory Quality (high-resolution, clear diagrams) Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Liquid-Cooled Displacement 700: 683 cc (41.7 cu. in.) Displacement 800: 760 cc (46.4 cu. in.) Bore X Stroke 700: 102 mm x 82 mm (4.02 in. x 3.23 in.) Bore X Stroke 800: 103 mm x 92.5 mm (4.06 in. x 3.64 in.) Compression Ratio 700: 10.0:1 Compression Ratio 800: 10.4:1 Performance Horsepower 700 Est: ~40 HP Horsepower 800 Est: ~50 HP Fuel System Induction: Electronic Fuel Injection (EFI) - Keihin or Mikuni throttle body Fuel Type: Unleaded gasoline, 87 octane minimum Ignition System: Electronic CDI with Digital Spark Advance 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with Engine Braking Gearing: H/L/N/R/P (High, Low, Neutral, Reverse, Park) Drive System: Shaft Drive Front Drive Engagement: Automatic All-Wheel Drive (AWD) Features Clutches: Primary and Secondary Clutch Assembly Belt Type: Specific PVT Belt (refer to manual for part numbers and dimensions) 📐 Dimensions Exterior Length X Width X Height 700/800: Approx. 85.1 x 49.5 x 48 in. (216 x 125.7 x 121.9 cm) Wheelbase: Approx. 50.5 in. (128.3 cm) Ground Clearance: Approx. 11.25 in. (28.6 cm) Cargo Rear Rack Capacity: 200 lbs (90 kg) Front Rack Capacity: 100 lbs (45 kg) Weights Dry Weight 700: Approx. 676 lbs (307 kg) Dry Weight 800: Approx. 705 lbs (320 kg) Towing Capacity: 1500 lbs (680 kg) Gcvw: 2500 lbs (1134 kg) 🛡️ Safety Features Ratings Atv Safety: Refer to Polaris owner's...
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Polaris ATV 2008 Sportsman 800 EFI X2 700 EFI Repair ManualPolaris ATV 2008 Sportsman 800 EFI X2 700 EFI Repair ManualPolaris ATV 2008 Sportsman 800 EFI X2 700 EFI Repair Manual
This manual provides comprehensive repair and service information for the 2008 Sportsman 800 EFI X2, Sportsman X-2 700 EFI, and Sportsman Touring 800 EFI models. A renowned American manufacturer has a strong heritage in powersports, and the Sportsman line is celebrated for its comfort, utility, and off-road capability. The X2 variant notably features a versatile 2-up seating configuration. These ATVs are engineered for a wide range of terrains and tasks, offering robust performance and reliability. This factory service manual is the definitive resource for maintaining and repairing your 2008 Sportsman. It covers all essential systems, including detailed procedures for the engine, fuel system, transmission, drivetrain, suspension, steering, brakes, and electrical systems. You will find step-by-step instructions for scheduled maintenance, component repair, disassembly and reassembly, and troubleshooting. With factory-level accuracy and detail, this manual equips owners and technicians with the knowledge necessary to keep their vehicle in optimal condition.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 800 EFI X2
Model Variant:
Sportsman 800 EFI, Sportsman X-2 700 EFI, Sportsman Touring 800 EFI
Year:
2008
Product Type:
Repair Manual / Service Manual
Codes
Manual Identifier:
Polaris Factory Service Manual
👋 Introduction
Market Position
Positioning:
The definitive factory service resource for owners and technicians of the 2008 Polaris Sportsman 800 EFI X2, 700 EFI X2, and Touring 800 EFI models.
Competitive Analysis
Comparison:
Outperforms aftermarket manuals in accuracy, completeness, and detail, providing factory-level information.
Key Features
Features:
Original factory data, comprehensive system coverage, detailed diagrams, and troubleshooting guides.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive repair, service, and technical information for 2008 Polaris Sportsman models.
Page Count
Total Pages:
388
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for the 700cc and 800cc ProStar EFI engines.
Fuel System:
EFI system, fuel pump, injectors, throttle body, and fuel tank service.
Cooling System:
Radiator, fan, thermostat, coolant specifications, and flushing procedures.
Transmission:
PVT (Polaris Variable Transmission) system, belt inspection, replacement, clutch service, and drivetrain.
Drivetrain:
AWD system, front differential, rear differential, driveshafts, and U-joints.
Suspension:
Front and rear suspension systems, shock absorbers, springs, bushings, and alignment.
Steering:
Handlebars, tie rods, steering rack, and linkage service.
Brakes:
Hydraulic brake system, master cylinders, calipers, rotors, brake fluid specifications, and bleeding procedures.
Electrical System:
Battery, charging system (stator, voltage regulator), starter motor, ignition system, lighting, and wiring diagrams.
Chassis And Body:
Frame, body panels, fenders, seat, racks, and cargo box (X2 specific) disassembly and reassembly.
Instruments And Controls:
Gauges, switches, controls, and accessory power outlets.
Troubleshooting:
Extensive diagnostic flowcharts and troubleshooting guides for common and uncommon issues.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, valve adjustments, and drive belt inspection.
Repair:
Step-by-step instructions for component repair, replacement, and overhaul of all major systems.
Diagnostics:
Detailed diagnostic procedures, fault codes (DTCs), and testing methodologies.
Assembly Disassembly:
Complete guidance on dismantling and reassembling the entire ATV.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds.
Detail Level:
Includes torque specifications, clearances, tolerances, and detailed diagrams.
Target Audience:
Professional technicians, experienced DIY mechanics, and serious ATV enthusiasts.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (assuming standard PDF creation)
Printable:
Yes
Print Quality
Quality:
Original Factory Quality (high-resolution, clear diagrams)
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve, Liquid-Cooled
Displacement 700:
683 cc (41.7 cu. in.)
Displacement 800:
760 cc (46.4 cu. in.)
Bore X Stroke 700:
102 mm x 82 mm (4.02 in. x 3.23 in.)
Bore X Stroke 800:
103 mm x 92.5 mm (4.06 in. x 3.64 in.)
Compression Ratio 700:
10.0:1
Compression Ratio 800:
10.4:1
Performance
Horsepower 700 Est:
~40 HP
Horsepower 800 Est:
~50 HP
Fuel System
Induction:
Electronic Fuel Injection (EFI) - Keihin or Mikuni throttle body
Fuel Type:
Unleaded gasoline, 87 octane minimum
Ignition
System:
Electronic CDI with Digital Spark Advance
🔧 Transmission
Standard
Type:
Polaris Variable Transmission (PVT) with Engine Braking
Gearing:
H/L/N/R/P (High, Low, Neutral, Reverse, Park)
Drive System:
Shaft Drive
Front Drive Engagement:
Automatic All-Wheel Drive (AWD)
Features
Clutches:
Primary and Secondary Clutch Assembly
Belt Type:
Specific PVT Belt (refer to manual for part numbers and dimensions)
📐 Dimensions
Exterior
Length X Width X Height 700/800:
Approx. 85.1 x 49.5 x 48 in. (216 x 125.7 x 121.9 cm)
Wheelbase:
Approx. 50.5 in. (128.3 cm)
Ground Clearance:
Approx. 11.25 in. (28.6 cm)
Cargo
Rear Rack Capacity:
200 lbs (90 kg)
Front Rack Capacity:
100 lbs (45 kg)
Weights
Dry Weight 700:
Approx. 676 lbs (307 kg)
Dry Weight 800:
Approx. 705 lbs (320 kg)
Towing Capacity:
1500 lbs (680 kg)
Gcvw:
2500 lbs (1134 kg)
🛡️ Safety Features
Ratings
Atv Safety:
Refer to Polaris owner's manual for specific safety guidelines and operation warnings.
Active Features
AWD:
Automatic All-Wheel Drive system for enhanced traction.
Engine Braking:
Provides downhill control and aids in deceleration.
Passive Features
Brakes:
Hydraulic disc brakes front and rear for reliable stopping power.
Lighting:
Halogen headlights and taillight for visibility.
Operator Presence:
Throttle safety lockout, brake lever lockout.
💡 Technology Features
Infotainment
Instrumentation:
Digital odometer, speedometer, trip meter, tachometer, fuel gauge, coolant temperature gauge, clock, service indicator.
Driver Assistance
Traction Control:
Not applicable for this model year.
Connectivity
Charging System:
12V DC charging system with accessory outlet for charging devices.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 100 hours or annually, whichever comes first. Refer to manual for specific oil type and capacity.
Air Filter:
Inspect every 50 hours, clean or replace as needed. More frequent if operated in dusty conditions.
Spark Plug:
Replace every 100 hours or annually.
Drive Belt:
Inspect every 100 hours for wear and damage, replace if necessary.
Fluid Specifications
Engine Oil:
Polaris PS-4 5W-50 Synthetic Ester or equivalent API SG or higher, JASO MA certified. (Manual specifies exact type and capacity).
Transmission Gearcase Oil:
Polaris Demand Drive LT Synthetic Fluid or equivalent SAE 75W-140 synthetic gearcase lubricant. (Manual specifies exact type and capacity).
Brake Fluid:
DOT 4 brake fluid.
Coolant:
50/50 mixture of Polaris Brand Antifreeze/Coolant or equivalent ethylene glycol-based antifreeze with corrosion inhibitors. (Manual specifies exact type).
Known Issues
Common Wear Items:
PVT belt wear, suspension bushings, tie rod ends, wheel bearings, ball joints.
Efi System:
Occasional issues with fuel pump or injectors requiring cleaning/replacement. Manual provides diagnostic steps.
📚 Vehicle History
Brand Heritage
Heritage:
Polaris Industries is a pioneering American manufacturer of powersports vehicles, known for its innovation in ATVs and snowmobiles.
Model Evolution
Sportsman Line:
The Sportsman line has a long history of popularity, known for its comfort, utility, and capability in various terrains.
X2 Variant:
The X2 variant introduced a unique 2-up seating capability with a conversion from a single rider to a passenger seat.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Polaris Sportsman models are consistently recognized for their utility, comfort, and off-road performance in industry reviews and rider surveys.
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