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Polaris Sportsman X2 700 800 EFI 800 TOURING 2008 Service Repair Manual

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The Polaris Sportsman X2 700 EFI, 800 EFI, and 800 TOURING models from 2008 represent robust All-Terrain Vehicles (ATVs) known for their versatility and capability. These models are engineered with powerful V-twin engines, an on-demand All-Wheel Drive system, and the unique X2 design, allowing for a convertible passenger or cargo mode. They offer a comfortable ride and are well-suited for recreational pursuits, utility tasks, and outdoor adventures, distinguishing themselves in a competitive market through their blend of performance and adaptability. This comprehensive Service and Repair Manual is designed to provide essential knowledge for owners and technicians alike. It covers a wide range of critical areas, including detailed engine diagnostics and repair, transmission and drivetrain maintenance, brake system servicing, and electrical system troubleshooting. The manual offers step-by-step instructions for routine maintenance, component replacement, and in-depth diagnostics, ensuring the Polaris Sportsman can be kept in optimal working condition, thereby maximizing its longevity and performance. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman X2 700 EFI / 800 EFI / 800 TOURING Year: 2008 Codes Vin Decoder Notes: VINs for this model year typically start with 4X4. 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) Target User: Recreational riders, utility users, outdoor enthusiasts, professional mechanics. Competitive Analysis Competitors 2008: Can-Am Outlander, Arctic Cat 700/1000, Yamaha Grizzly, Suzuki King Quad. Key Features Unique Selling Points: Versatile X2 design with convertible passenger/cargo mode, powerful V-twin engines, Polaris on-demand AWD system, comfortable ride. Manual Value Proposition: Provides essential knowledge for owners and technicians to maintain, diagnose, and repair their Polaris Sportsman, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Download Pages: Estimated 300-500 pages (typical for this level of detail) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, disassembly, assembly, torque specifications, timing, cooling system, lubrication system, fuel delivery, ignition system, emissions control. Transmission: CVT (Continuously Variable Transmission) inspection, service, belt replacement, clutch assembly, gearbox maintenance, differential service. Drivetrain: All-wheel drive (AWD) system, front and rear driveshafts, CV joints, gearcases, prop shafts, U-joints, maintenance and repair procedures. Brakes: Hydraulic brake system, front and rear calipers, master cylinder, brake lines, bleeding procedures, parking brake adjustment, component replacement. Electrical: Wiring diagrams, starter motor, alternator, battery, ignition system, lighting, instrumentation, charging system, EFI control module, fault diagnosis. Suspension: Front and rear suspension components, shocks, struts, control arms, bushings, wheel alignment, bearing service, adjustment procedures. Steering: Steering column, tie rods, steering rack, power steering system (if equipped), adjustments, maintenance. Fuel System: Fuel pump, fuel filter, fuel injectors, throttle body, fuel pressure regulator, EFI system troubleshooting. Cooling System: Radiator, fan, coolant hoses, water pump, thermostat, flush and fill procedures, temperature sensor diagnostics. Bodywork And Chassis: Frame inspection, body panel removal/installation, seat adjustment, storage compartment access, accessory mounting. Accessories And Features: Dump box operation (X2), tilt bed operation, lighting systems, electrical accessory hookups. Procedures Included Maintenance: Routine oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake system checks, tire pressure, battery maintenance, drive belt inspection. Troubleshooting: Systematic diagnostic procedures for engine performance issues, electrical faults, starting problems, driveability concerns, common failures. Repair: Step-by-step instructions for component replacement, rebuilds, and adjustments across all covered systems. Diagnostics: Diagnostic Trouble Codes (DTCs) interpretation for EFI system, electrical system troubleshooting guides, flow charts. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth Level: Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed electrical system diagnostics and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (typically, depending on PDF creation) Printable: Yes Print Quality Image Resolution: High-resolution, clear illustrations and diagrams. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Quality: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type 700: 700cc V-twin, 4-stroke, SOHC, liquid-cooled Engine Type 800: 800cc V-twin, 4-stroke, SOHC, liquid-cooled Bore X Stroke 700: Approx. 79.0 mm x 67.2 mm Bore X Stroke 800: Approx. 83.0 mm x 70.0 mm Compression Ratio 700: Approx. 9.5:1 Compression Ratio 800: Approx. 9.5:1 Ignition: Electronic Ignition Performance Horsepower 700: Approx. 50 HP Horsepower 800: Approx. 55 HP Torque 700: Approx. 44 lb-ft Torque 800: Approx. 48 lb-ft Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane minimum) Fluid Capacities Engine Oil Capacity: Approx. 2.25 Quarts (2.1 Liters) with filter change Fluid Specifications Engine Oil Type: SAE 10W-40, API SG or higher (Polaris recommends specific ester-based synthetic blend) Coolant Type: Ethylene Glycol based antifreeze/coolant (Polaris recommended type or equivalent) 🔧 Transmission Standard Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive Modes: 2WD/AWD (On-Demand) Gear Selection: High, Low, Neutral, Reverse, Park Optional Differentials: Front: Polaris Automatic''(Polaris Sensing Variable AWD System''; Rear: Locked Features Cv Belt Maintenance: Regular inspection and replacement recommended by Polaris. Fluid Specifications Transmission Fluid Type: Refer...
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Polaris Sportsman X2 700 800 EFI 800 TOURING 2008 Service Repair ManualPolaris Sportsman X2 700 800 EFI 800 TOURING 2008 Service Repair ManualPolaris Sportsman X2 700 800 EFI 800 TOURING 2008 Service Repair ManualPolaris Sportsman X2 700 800 EFI 800 TOURING 2008 Service Repair Manual
The Polaris Sportsman X2 700 EFI, 800 EFI, and 800 TOURING models from 2008 represent robust All-Terrain Vehicles (ATVs) known for their versatility and capability. These models are engineered with powerful V-twin engines, an on-demand All-Wheel Drive system, and the unique X2 design, allowing for a convertible passenger or cargo mode. They offer a comfortable ride and are well-suited for recreational pursuits, utility tasks, and outdoor adventures, distinguishing themselves in a competitive market through their blend of performance and adaptability. This comprehensive Service and Repair Manual is designed to provide essential knowledge for owners and technicians alike. It covers a wide range of critical areas, including detailed engine diagnostics and repair, transmission and drivetrain maintenance, brake system servicing, and electrical system troubleshooting. The manual offers step-by-step instructions for routine maintenance, component replacement, and in-depth diagnostics, ensuring the Polaris Sportsman can be kept in optimal working condition, thereby maximizing its longevity and performance.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman X2 700 EFI / 800 EFI / 800 TOURING
Year:
2008
Codes
Vin Decoder Notes:
VINs for this model year typically start with 4X4.
👋 Introduction
Market Position
Category:
All-Terrain Vehicle (ATV)
Target User:
Recreational riders, utility users, outdoor enthusiasts, professional mechanics.
Competitive Analysis
Competitors 2008:
Can-Am Outlander, Arctic Cat 700/1000, Yamaha Grizzly, Suzuki King Quad.
Key Features
Unique Selling Points:
Versatile X2 design with convertible passenger/cargo mode, powerful V-twin engines, Polaris on-demand AWD system, comfortable ride.
Manual Value Proposition:
Provides essential knowledge for owners and technicians to maintain, diagnose, and repair their Polaris Sportsman, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF Download
Pages:
Estimated 300-500 pages (typical for this level of detail)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, disassembly, assembly, torque specifications, timing, cooling system, lubrication system, fuel delivery, ignition system, emissions control.
Transmission:
CVT (Continuously Variable Transmission) inspection, service, belt replacement, clutch assembly, gearbox maintenance, differential service.
Drivetrain:
All-wheel drive (AWD) system, front and rear driveshafts, CV joints, gearcases, prop shafts, U-joints, maintenance and repair procedures.
Brakes:
Hydraulic brake system, front and rear calipers, master cylinder, brake lines, bleeding procedures, parking brake adjustment, component replacement.
Electrical:
Wiring diagrams, starter motor, alternator, battery, ignition system, lighting, instrumentation, charging system, EFI control module, fault diagnosis.
Suspension:
Front and rear suspension components, shocks, struts, control arms, bushings, wheel alignment, bearing service, adjustment procedures.
Steering:
Steering column, tie rods, steering rack, power steering system (if equipped), adjustments, maintenance.
Fuel System:
Fuel pump, fuel filter, fuel injectors, throttle body, fuel pressure regulator, EFI system troubleshooting.
Cooling System:
Radiator, fan, coolant hoses, water pump, thermostat, flush and fill procedures, temperature sensor diagnostics.
Bodywork And Chassis:
Frame inspection, body panel removal/installation, seat adjustment, storage compartment access, accessory mounting.
Accessories And Features:
Dump box operation (X2), tilt bed operation, lighting systems, electrical accessory hookups.
Procedures Included
Maintenance:
Routine oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake system checks, tire pressure, battery maintenance, drive belt inspection.
Troubleshooting:
Systematic diagnostic procedures for engine performance issues, electrical faults, starting problems, driveability concerns, common failures.
Repair:
Step-by-step instructions for component replacement, rebuilds, and adjustments across all covered systems.
Diagnostics:
Diagnostic Trouble Codes (DTCs) interpretation for EFI system, electrical system troubleshooting guides, flow charts.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Technical Depth
Depth Level:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed electrical system diagnostics and wiring diagrams.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically, depending on PDF creation)
Printable:
Yes
Print Quality
Image Resolution:
High-resolution, clear illustrations and diagrams.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Quality:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type 700:
700cc V-twin, 4-stroke, SOHC, liquid-cooled
Engine Type 800:
800cc V-twin, 4-stroke, SOHC, liquid-cooled
Bore X Stroke 700:
Approx. 79.0 mm x 67.2 mm
Bore X Stroke 800:
Approx. 83.0 mm x 70.0 mm
Compression Ratio 700:
Approx. 9.5:1
Compression Ratio 800:
Approx. 9.5:1
Ignition:
Electronic Ignition
Performance
Horsepower 700:
Approx. 50 HP
Horsepower 800:
Approx. 55 HP
Torque 700:
Approx. 44 lb-ft
Torque 800:
Approx. 48 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane minimum)
Fluid Capacities
Engine Oil Capacity:
Approx. 2.25 Quarts (2.1 Liters) with filter change
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher (Polaris recommends specific ester-based synthetic blend)
Coolant Type:
Ethylene Glycol based antifreeze/coolant (Polaris recommended type or equivalent)
🔧 Transmission
Standard
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive Modes:
2WD/AWD (On-Demand)
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Differentials:
Front: Polaris Automatic''(Polaris Sensing Variable AWD System''; Rear: Locked
Features
Cv Belt Maintenance:
Regular inspection and replacement recommended by Polaris.
Fluid Specifications
Transmission Fluid Type:
Refer to manual for specific PVT fluid type and quantity, often specialized.
📐 Dimensions
Exterior
Length:
Approx. 81.5 in (207 cm)
Width:
Approx. 48.5 in (123 cm)
Height:
Approx. 47.2 in (119.9 cm)
Wheelbase:
Approx. 50.4 in (128 cm)
Ground Clearance:
Approx. 11.5 in (29.2 cm)
Weights
Dry Weight:
Approx. 640-660 lbs (290-300 kg) depending on model variant
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear X2:
200 lbs (90 kg)
Cargo Capacity X2 Mode:
400 lbs (181 kg) in dump box
🛡️ Safety Features
Ratings
Atv Safety Standards:
Designed to meet ANSI/SVIA 1-2004 and B71.2-2003 standards.
Active Features
Braking System:
Hydraulic Disc Brakes (front and rear), Engine Braking
AWD System:
On-Demand All-Wheel Drive enhances traction.
Passive Features
Lighting:
Dual headlights, brake light/taillight.
Operator Protection:
Handlebar handguards, comfortable seating position.
💡 Technology Features
Infotainment
Instrumentation:
Digital instrument cluster displaying speed, RPM, fuel level, gear selection, AWD status, engine hours, and diagnostic indicators.
Driver Assistance
Powertrain Management:
Electronic Fuel Injection (EFI) optimizes power delivery and fuel efficiency.
Connectivity
Accessory Power:
Factory pre-wired for accessories, providing power ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or annually, whichever comes first.
Air Filter Service:
Clean every 50 hours; replace as needed.
Spark Plug Replacement:
Every 100 hours or annually.
Cv Belt Inspection:
Every 50 hours; replace at manufacturer's recommended mileage/hours or when worn.
Valve Adjustment:
Refer to manual for specific intervals, typically every 100-200 hours.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type Front Rear:
Polaris Demand Drive Fluid or equivalent SAE 80W-90 GL-5 gear oil (check manual for specifics).
Known Issues
Common Wear Items:
CV Axle boots, drive belts, ball joints, wheel bearings, brake pads, sway bar links (depending on usage).
Efi Related Concerns:
Occasional throttle body cleaning or sensor issues can arise with high usage.
Electrical System Quirks:
Corrosion on connectors can sometimes cause intermittent issues, especially in wet environments.
📚 Vehicle History
Brand Heritage
Polariss Atv Legacy:
Polaris has a long history in snowmobiles and ATVs, establishing itself as a leading manufacturer of off-road vehicles.
Model Evolution
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris, known for its comfort, utility, and capability. The X2 variant introduced the unique convertible cargo/passenger bed.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the USA.
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Polaris Sportsman models consistently receive positive reviews for their robust performance, comfort, and utility in the ATV market.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction for durability and capability.
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