Polaris ATV 2004-2010 Sportsman 700 800 X2 EFI Repair Manual

XI QUICK REFERENCE DATA MODEL: YEAR: VIN NUMBER: ENGINE SERIAL NUMBER: CARBURETOR SERIAL NUMBER: GEARCASE/TRANSMISSION NUMBER: BULB AND FUSE SPECIFICATIONS Item Speciﬁcation Brake light 2002-2003 models 26.9 watts 2004-on models except X2 and Touring models 8.26 watts 2007-on X2 and Touring models 8.26 watts × 2 Headlight High beam (headlight pod) 50 watts Low beam (grill) All 2002-2007 models except X2 models 27 watts × 2 2007 X2 models and 2008-on models 37 watts × 2 Taillight 2002-2003 models 8.26 watts 2004-on models except X2 and Touring models 26.9 watts 2007-on X2 and Touring models 26.9 watts × 2 Worklight (models so equipped) 13 watts × 2 Fuses 2002-2004 600 and 700 models Fan 20 amp Harness 20 amp 2004 700 EFI models Fan 20 amp Harness 20 amp Fuel pump/ECU 15 amp Instrument cluster/voltage regulator 6 amp 2005 600, 700 and MV7 models Circuit breakers within the voltage regulator 2005-on EFI, EFI X2 and EFI Touring models Fan (circuit breaker) 20 amp Accessory power 20 amp Chassis power 20 amp EFI power 15 amp Instrument cluster/ECU 5 amp WHEEL AND TIRE SPECIFICATIONS* Item Speciﬁcation Wheel/tire size 2002-2004 600 and 700 models, 2004 700 EFI models, X2 and Touring models Front 25 × 8 – 12 Rear 25 × 11 – 12 MV7 models Front 25 × 8 – 12 Rear 25 × 10 – 12 2005-on 700 models Front 24 × 8 – 12 Rear 24 × 11 – 12 (continued)

XII WHEEL AND TIRE SPECIFICATIONS* (continued) Item Specification Wheel/tire size (continued) 2005-on 600, 700 and 800 EFI models Front 26 × 8 – 12 Rear 26 × 11 – 12 Wheel pattern Front 4-156 Rear 4-156 Tire tread minimum depth Front 3.0 mm (1/8 in.) Rear 3.0 mm (1/8 in.) Tire pressure (cold) Front 34.5 kPa (5 psi) Rear 34.5 kPa (5 psi) Toe out 0-0.159 mm (0-1/16 in.) Toe alignment 0.03-0.06 mm (1/8-1/4 in.) *Tire and wheel specifications are for original equipment tires. Aftermarket tires may require different inflation pressure. The use of tires other than those specified by the manufacturer may cause instability. RECOMMENDED LUBRICANTS, FLUIDS AND GREASE Fuel system Pump octane (R+M / 2) 87 non-oxygenated or 89 oxygenated Fuel tank capacity (including reserve) 2002-2003 models 17.9 L (4.75 gal.) 2004 models; 2005-on 600 and 700 models 16 L (4.25 gal.) MV7 models Front tank 16 L (4.25 gal.) Rear tank 15 L (4.0 gal.) 2005-on EFI models 15.6 L (4.13 gal.) X2 and Touring models 22.7 L (6.0 gal.) Cooling system Coolant type Polaris Premium 60/40 Antifreeze/Coolant (premixed) or an equivalent high-quality aluminum-compatible coolant mixed with distilled water in a 50:50 to 60:40 ratio Capacity All models except 2008-on 800 EFI, X2 and Touring models 3.0 L (3.2 qt.) X2 and Touring models 3.2 L (3.4 qt.) 2008-on 800 EFI models 3.4 L (3.6 qt.) Engine oil Type All 2002-2007 models Polaris Premium 4 All Season Synthetic/0W40 All 2008-on models Polaris PS4 Plus 2W50 Synthetic Capacity 1.9 L (2 qt.) Front gearcase Lubricant type Polaris Demand Drive LT Premium Hub Fluid Capacity 2002-2006 models 150 ml (5 oz.) 2007-on Centralized Hilliard models 265 ml (8.97 oz.) 2007-2009 ADC models 275 ml (9.3 oz.) Rear gearcase Lubricant type Polaris ATV Angle Drive Fluid Capacity All models except MV7 models 150 ml (5 oz.) MV7 models 300 ml (10 oz.) Transmission Lubricant type All models except X2 and Touring models Polaris AGL Synthetic Gearcase Lubricant X2 and Touring models Polaris Premium Synthetic Gear Case Lube (continued)

XIII RECOMMENDED LUBRICANTS, FLUIDS AND GREASE (continued) Transmission (continued) Capacity 2002-early 2004 models 400 ml (13.5 oz.) Late 2004-on models except X2 and Touring models 450 ml (15.2 oz.) X2 and Touring models 946.3 ml (32 oz.) Grease types Front drive axle U-joint Polaris U-joint Grease* Front drive shaft Polaris U-joint Grease* Front hub strut and A-arm Polaris All Season Grease* Rear bearing carrier and control arms Polaris All Season Grease* Brake ﬂuid 2002-2007 models DOT 3 2008-on models DOT 4 *Or a similar NLGL No. 2 grease. MAINTENANCE AND TUNE-UP SPECIFICATIONS Item Speciﬁcation Battery Capacity 30 amp hr Maximum current draw (key off) 10 mA Brake pad thickness (service limit) 4.6 mm (0.181 in.) Brake pedal free play 3.2-6.35 mm (1/8 – 1/4 in.) Brake pedal height (with 50 pound weight) 25.4 mm (1.0 in.) or more Cooling system System test pressure 68.95 kPa (0.689 kg cm 2 [10 psi] Radiator cap relief pressure 90 kPa (0.90 kg cm 2 [13 psi]) Ignition timing 2002 700 models 25° BTDC @ 2500-3500 rpm 2003 600 models 25° BTDC @ 2500-3500 rpm 700 models 32° BTDC @ 5560-5960 rpm 2004 Early 600 models 13° BTDC @ 950-1450 rpm Early 700 models 13° BTDC @ 1000-1400 rpm Late 600 and 700 models 13° BTDC @ 1200 rpm 700 EFI models 13° BTDC @ 1200 rpm All 2005-on models except X2 and Touring models 13° BTDC @ 1200 rpm X2 and Touring models Variable, ECU controlled Engine compression pressure All models except 800 EFI, X2 and Touring models 1034-1172 kPa (150-170 psi) 800 EFI, X2 and Touring models 1034-1379 kPa (150-200 psi) Engine idle speed 2002 700 models 900-1300 rpm 2003 600 and 700 models 1000-1200 rpm 2004 Early 600 and early 700 models 1050-1150 rpm Late 600 and late 700 models 1150-1250 rpm 700 EFI models 1050-1250 rpm 2005-on 600, 700 and MV7 models 1150-1250 rpm 700 EFI, 800 EFI, X2 and Touring models 1050-1250 rpm Engine oil pressure @ 5500 rpm (engine hot) 2002-2003 models Standard 234 kPa (34 psi) Minimum 172 kPa (25 psi) 2004-on models Standard 269 kPa (39 psi) Minimum 241 kPA (35 psi) Spark plug Type RC7YC Gap 0.9 mm (0.035 in.) Throttle cable free play 1.6-3.18 mm (1/16-1/8 in.)

XIV MAINTENANCE AND TUNE-UP TORQUE SPECIFICATIONS Item N•m in.-lb. ft.-lb. Cylinder head bolts 2002-2003 models 81-87 – 60-64 2004-on models 42-53 plus 1/4 turn – 31-39 plus 1/4 turn Engine oil Oil drain bolt* 2002-2003 models 27-30 – 20-22 2004 models 19-25 – 14-18 2005-on models 16 – 12 Oil pressure plug* 27-33 – 20-24 Front gearcase Oil drain bolt* – 2002-2004 models 19 – 14 2005-on models 15 – 11 Front master cylinder Top cover bolts* 2002-2006 models 0.56 5 – 2007-on models 0.79 7 – Handlebar clamp bolt/nut 15-18 – 11-13 Hub nut Front 95 – 70 Rear 108 – 80 Rear gearcase Gearcase cover bolt 34 – 25 Oil drain bolt* 2002-2004 models 19 – 14 2005-on models 19-24 – 14-18 Oil ﬁller bolt* 2002-2004 models 19 – 14 2005-on models 19-24 – 14-18 Spark plug 2002-2004 models 19 – 14 2005-on models 24 – 18 Tie rod locknut 17-19 – 12-14 Transmission drain bolt* – 2002-2004 models 19-24 – 14-18 2005-2007 models except X2 models 14-19 – 10-14 2008-on models except X2 and Touring models 19 – 14 2007-2009 X2 and Touring models 27-34 – 20-25 Transmission ﬁller bolt – 2002-2004 models 19-24 – 14-18 2005-2007 models except X2 models 14-19 – 10-14 2008-on models except X2 and Touring models 19 – 14 2007-2009 X2 and Touring models 27-34 – 20-25 Wheel nut 2002-2004 600, 700 and 700 EFI models 41 – 30 2005-on 600, 700 and MV7 models 37 – 27 2005-on 700 EFI, 800 EFI, and X2 and Touring models Steel wheel 37 – 27 Aluminum wheel 122 – 90 *Refer to text.

2 CHAPTER ONE 4. If welding or brazing on the ATV, remove the fuel tank to a safe distance at least 50 ft. (15 m) away. 5. Use the correct type and size of tools to avoid damaging fasteners. 6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment. 7. When loosening a tight fastener, be guided by what would happen if the tool slips. 8. When replacing fasteners, make sure the new fasteners are the same size and strength as the original ones. 9. Keep the work area clean and organized. 10. Wear eye protection anytime the safety of eyes is in question. This includes procedures that involve drilling, grinding, hammering, compressed air and chemicals. 11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving equipment. 12. Do not carry sharp tools in clothing pockets. 13. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B) and electrical (Class C) fires. 14. Do not use compressed air to clean clothes, the ATV or the work area. Debris may be blown into eyes or skin. Never direct compressed air at anyone. Do not allow chil- dren to use or play with any compressed air equipment. 15. When using compressed air to dry rotating parts, hold the part so it does not rotate. Do not allow the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The part may disintegrate or become damaged, causing serious injury. 16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain asbestos. In addition, some types of insulating materials and gaskets may contain asbestos. Inhaling asbestos particles is hazardous to health. 17. Never work on the ATV while someone is working under it. 18. When lifting an ATV with a jack, make sure it is secure before walking away. Handling Gasoline Safely Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. Because gasoline is used so often, many people forget it is hazardous and always present in the fuel tank, fuel lines, and carburetors or throttle bodies. To avoid a disastrous accident when working on or around the fuel system, carefully observe the following precautions: 1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section. 2. When working on the fuel system, work outside or in a well-ventilated area. 3. Do not refuel or service the fuel system while the ATV is near open flames, sparks or where someone is smoking. Gasoline vapor is heavier than air; it collects in low areas and is more easily ignited than liquid gasoline. 4. Allow the engine to cool completely before working on any fuel system component. 1 2 3 4

Polaris ATV 2004-2010 Sportsman 700 800 X2 EFI Repair Manual

You're Reading a Preview

Recently Viewed