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2008 SPORTSMAN X2 700 /800 EFI /800 TOURING

SERVICE MANUAL

FOREWORD

This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator’s perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service

procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as

specified.

Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100

Hwy 55 Medina Minnesota 55340.

2008 Sportsman X2 700 / 800 EFI / 800 Touring Service Manual PN 9921323

© Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting

or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Manuals and User Guides for Polaris Sportsman 800 EFI. We have 7 Polaris Sportsman 800 EFI manuals available for free PDF download: Service Manual, Owner’s Manual, Owner’s Manual For Maintenance And Safety

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(Ocr-Read Summary of Contents of some pages of the Polaris Sportsman 800 EFI 4×4 2012 Document (Main Content), UPD: 09 July 2023)

  • 142, Polaris Sportsman 800 EFI 4×4 2012 4.8 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Fuel Tank Assembly FUEL SYSTEM — GENERAL
    …

  • 306, 7.40 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. MIDDLE GEARCASE (6X6) Removal 1. Place ATV on a level surface and place transmission in ‘PARK’. 2. Loosen both middle wheel nuts. 3. Loosen both middle center hub nuts. 4. Lift and safely support rear of ATV so that the wheels are off the ground. 5. Remove both wheels and center hub nuts. NOTE: Hub removal is not required to remove CV shafts. 6. Remove both upper hub carrier bolts from the A-arm. Tilt c…

  • 389, 9 9.5 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. BRAKE SYSTEM EXPLODED VIEW (6X6) Brake System Exploded View BRAKES
    …

  • 362, 8.22 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 14. Install the lockout disc onto the shift drum shaft. Be sure to install the lockout disc with the raised edge facing outward. 15. Install the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward. 16. Install the detent pawl onto the shift shaft and carefully install the compression spring. 17. Install a new O-ring on each shift sh…

  • 238, Polaris Sportsman 800 EFI 4×4 2012 6.22 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 4. Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Spider Torque: 200 ft-lbs (271 Nm) CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider. Any misalignment will alter clutch balance. Inverting the clutch while initially tightening the spider will he…

  • 330, 7.64 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 5. Using a soft-faced hammer, or brass drift, strike the inner race of the joint to drive the joint off the drive shaft. Be sure to tap evenly around the joint to avoid binding. IMPORTANT: Tap on inner race only! 6. Make sure the circlip is on the shaft and not left in the joint. 7. Remove the CV boot from the shaft. CAUTION Complete disassembly of the CV joint is NOT recommended…

  • 233, 6 6.17 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Shift Weight Inspection 1. Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and free of dents or gall marks. Inspect the weight pivot bore and bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts and nuts. WARNING The clutch assemb…

  • 419, 10 10.5 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. INSTRUMENT CLUSTER Overview Introduction Refer To Illustration 1: The Polaris ATV Instrument Cluster is powered by battery voltage (12 Vdc) and requires inputs from the engine RPM, transmission gear, and speed sensor for proper operation. Two harnesses plug into the cluster head; one from the speed sensor, and one from the vehicle main harn…

  • 402, 9.18 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. FRONT CALIPER Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 1. Loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line. 2. Push upper pad retainer pin inward and slip brake pads past edge. Loosen pad adjuster. 3. Remove mounting bracket, pin assembly and dust boot. 4. Remove piston,…

  • 18, 1.12 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. SAE Tap / Drill Sizes THREAD SIZE DRILL SIZE THREAD SIZE DRILL SIZE #0–80 3/64 1/2–13 27/64 #1–64 53 1/2–20 29/64 #1–72 53 9/16–12 31/64 #2–56 51 9/16–18 33/64 #2–64 50 5/8–11 17/32 #3–48 5/64 5/8–18 37/64 #3–56 45 3/4–10 21/32 #4–40 43 3/4–16 11/16 #4–48 42 7/8–9 49/64 #5–40 38 7/8–14 13/16 #5–44 37 1–8 7/8 #6–32 36 1–12 59/64 …

  • 189, 5 5.7 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 8. To reinstall the front bumper, reverse order of removal. Be sure that the 4 plastic locking tabs of the front fender are properly seated into the 4 slots of the upper front bumper. 9. Torque the (6) T27 fasteners to specification. Font Bumper Retaining Fasteners: 5 ft-lbs (7 Nm) Mud Guard Removal / Installation 1. Remove front bump…

  • 401, Polaris Sportsman 800 EFI 4×4 2012 9 9.17 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Removal / Replacement NOTE: To reduce the possibility of warping, try removing the brake disc mounting bolts before applying heat to the bolts. 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4. Install disc on hub. 5. Install new bolts and …

  • 112, 3.52 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 4. Measure camshaft journal outside diameters (O.D.). Camshaft Journal O.D. : A. (Mag): 1.654″ ± .00039″ (42 ± .010 mm) B. (Ctr.): 1.634″ ± .00039″ (41.50 ± .010 mm) C. (PTO): 1.614″ ± .00039″ (41 ± .010 mm) 5. Measure ID of camshaft journal bores. Camshaft Journal Bore I.D.: (Mag): 1.656″ ± 0.00039″ (42.07± 0.010 mm) (Ctr.) 1.637″ ± 0.00039″ (41.58 �…

  • 17, 1.11 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. MISC. NUMBERS/CHARTS Conversion Table UNIT OF MEASURE MULTIPLIED BY CONVERTS TO ft-lbs x 12 = in-lbs in-lbs x 0.0833 = ft-lbs ft-lbs x 1.356 = Nm in-lbs x 0.0115 = kg-m Nm x 0.7376 = ft-lbs kg-m x 7.233 = ft-lbs kg-m x 86.796 = in-lbs kg-m x 10 = Nm inch x 25.4 = mm mm x 0.03937 = inch inch x 2.54 = cm mile (mi) x 1.6 = km km x 0.6214 = mile ounces …

  • 477, IX IX.1 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. A A-Arm Replacement ………………………………………. 5.22 Accessory Power Wiring ……………………………….. 10.41 Active Descent Control (ADC) Coil …………………… 10.23 Active Descent Control Gearcase ……………………… 7.24 ADC Gearcase Piston Service ………………………….. 7.32 ADC Gearcase, Di…

  • 139, Polaris Sportsman 800 EFI 4×4 2012 4 4.5 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. EFI System Exploded View FUEL SYSTEM — GENERAL
    …

  • 283, 7 7.17 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 12. Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cut-grooves of the ring gear. NOTE: Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves. 13. Install the output hub and cover plate assembly with a new o-ring (arrow) onto the gearcase. NOTE: Verify t…

  • 409, 9 9.25 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 9. Measure the inside diameter of the rear caliper. The caliper body is a 2-step piston. The rear step is measured as well as the outside step. Rear Caliper Piston Bore I.D. Inner Bore Service Limit: .94” (23.88 mm) Outer Bore Service Limit: 1.5” (38.1 mm) 10. Inspect caliper piston bore for scratches, severe corrosion, or gall…

  • 426, 10.12 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 3. The word “Wait” will appear, the EFI module is now searching for blink codes. If any blink codes are stored they will display in numerical order on the instrument cluster. NOTE: The check engine icon will flash during this mode. 4. The word “End” will display after all of the codes have been displayed. NOTE: A list of applicable codes is shown on t…

  • 339, 7 7.73 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. U-JOINT SERVICE Disassembly WARNING Always wear eye protection when working with spring- tensioned components 1. Remove internal or external snap ring from all bearing caps. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting (if equipped) and mark inner and outer yoke for correct re-positioning during installation. 2. Support inner y…

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