2008 Polaris Sportsman 500 EFI X2 Touring H.O. ATV Service Manual

Description

This 2008 Polaris Sportsman 500 EFI X2 Touring H.O. ATV Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2008 Polaris Sportsman 500 ATVs.

Polaris ATV Repair Manual Coverage

2008 Polaris Sportsman 500 EFI

2008 Polaris Sportsman 500 EFI Scandinavian

2008 Polaris Sportsman 500 HO

2008 Polaris Sportsman Touring 500 EFI

2008 Polaris Sportsman Touring 500 EFI Quadricycle

Cover photo shown is of original cover.  Since Polaris now prints on demand, the actual cover may vary from this photo.

Workshop Manual Table of Contents

General
Maintenance
Engine
Fuel System
Body / Suspension
Clutch
Transmission
Final Drive
Brakes
Electrical
International

Index of Topics

Chapter 1 General Information
Model Number Information
Model Number
Engine Designation Numbers
Vehicle Identification Number (‌VIN)
Transmission ID Location
Engine And Machine Serial Numbers
Publications
Paint Codes
Replacement Keys
2008 Sportsman 500
Model Number: A08mh50ax, Az
2008 Sportsman 500 EFI
Model Number: A08mn50af, An, Aq, As, Ax
2008 Sportsman X-2 500 EFI
Model Number: A08tn50ax, Az / A08tn50ea
2008 Sportsman Touring 500 EFI
Model Number: A08dn50af, As, Az / A08dn50ea
Misc Numbers/charts
Standard Torque Specifications
Sae Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Conversion Table
Glossary Of Terms

Chapter 2 Maintenance
Maintenance
Periodic Maintenance Chart
Maintenance Chart Key
Periodic Maintenance Chart
Lubrication / Fluids
Sportsman Component Locations
Sportsman X2-touring Component Locations
Polaris Lubricants, Maintenance And Service Products
Polaris Lubricant Symbol Identification
Pre-ride / Daily Inspection
Lubrication Components
Front Gearcase Lubrication
Transmission Lubrication
Adc Differential Hydraulic Circuit Fluid Change
Vehicle Inspection
Shift Link Rod Inspection
Throttle Inspection
Throttle Cable / Electronic Throttle Control Adjustment
Fuel System
Fuel Lines
Vent Lines
Fuel Filter
Choke (enricher) Adjustment – (500 Carb)
Compression Test
Engine Mounts
Spark Plug
Active Descent Control (adc) Reservoir Level
Battery Maintenance
Liquid Cooling System Overview
Coolant Strength / Type
Cooling System Hoses
Radiator/grill Screen
Cooling System Pressure Test
Coolant Level Inspection
Radiator Coolant Level Inspection
Air Filter/pre-filter Service
Air Box Sediment Tube
Breather Filter Inspection
Breather Hose
Recoil Housing
Engine Oil Level
Oil And Filter Change
Oil Pump Priming Procedure
Valve Clearance
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Steering
Tie Rod End/steering Inspection
Camber And Caster
Wheel Alignment
Toe Alignment Adjustment
Exhaust Pipe
Brake System Inspection
Brake Pad Inspection
Hose/fitting Inspection
Auxiliary Brake Testing
Auxiliary Brake Adjustment (hydraulic)
Suspension Spring Preload Adjustment
Front Suspension
Cv Shaft Boot Inspection
Controls
Wheels
Wheel, Hub, And Spindle Torque Table
Wheel Removal Front Or Rear
Wheel Installation
Tire Pressure
Tire Inspection
Frame, Nuts, Bolts, Fasteners
Storage Compartments
Winch Operation (if Equipped)
Atv Cleaning & Storage
Sportsman 500 Carbureted Maintenence
Choke (enricher) Adjustment
Pilot Screw
Pilot Screw Adjustment
Idle Speed Adjustment
Fuel Filter
Carburetor Draining
Maintenance Schedule

Chapter 3 Engine
Specifications
Torque Specifications
Special Tools
Engine Fastener Torque Patterns
Engine Service Data
Engine Service Data
General Engine Service
Piston Identification
Cooling System Specifications
Cooling System
Accessible Components
Engine Removal (typical)
Engine Installation Notes
Cylinder Hone Selection/honing Procedure
Honing To Oversize
Cleaning The Cylinder After Honing
Crankshaft Straightening
Engine Lubrication- Eh 50pl
Oil Pressure Test – Eh 50pl
Oil Pump Priming Procedure
Oil Flow-eh50pl
Eh50pl Oil Flow Diagram
Eh50pl Engine Exploded Views
Engine Disassembly
Cam Chain Tensioner/rocker Arm/ Camshaft Removal
Cam Chain Tensioner Inspection
Rocker Arm/shaft Inspection
Camshaft Removal
Automatic Compression Release Removal/inspection
Automatic Compression Release Installation
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Exploded View, Eh50pl
Cylinder Head Inspection
Cylinder Head Warp
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Clearance Adjustment
Cylinder/piston Removal And Inspection
Piston Removal
Cylinder Inspection
Piston-to-cylinder Clearance
Piston/rod Inspection
Piston Ring Installed Gap
Crankcase Disassembly
Starter Drive Removal/inspection
Flywheel/stator Removal/inspection
Cam Chain/tensioner Blade
One Way Valve Removal
Crankcase Separation
Oil Pump Removal/inspection
Oil Pump Assembly
Counter Balancer Shaft Removal/inspection
Crankshaft Removal/inspection
Crankcase Bearing Inspection
Pump Shaft Oil Seal/water Pump Mechanical Seal Removal
Crankcase Inspection
Bearing Installation
End Play Inspection/adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
Engine Reassembly
Pump Shaft Oil Seal Installation
Crankshaft/counter Balance/oil Pump Installation
Crankcase Assembly
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal – Engine Installed
One Way Valve Installation
Cam Chain Drive Sprocket Installation
Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head Installation
Cam Chain/camshaft Installation
Camshaft Timing
Camshaft Timing
Cam Chain Tensioner Installation
Stator, Flywheel And Starter Drive Installation
Rocker Shaft/rocker Arm Assembly Installation
Thermostat Installation
Oil Pipes
Recoil
Recoil Disassembly/inspection
Recoil Assembly
Troubleshooting
Spark Plug Fouling
Engine
Cooling System

Chapter 4 Fuel Injection
Special Tools
Part Numbers / Descriptions
EFI Service Notes
EFI System Exploded View
EFI System
Component Locations/identification
Fuel Tank
Exploded View
Electronic Fuel Injection
EFI Operation Overview
Initial Priming / Starting Procedure
Fuel Lines
Quick Connect Removal/installation
Electronic Control Unit (ecu)
Operation Overview
Ecu Replacement
Ecu Service
Fuel Pump Assembly
Operation/testing
Fuel Pump Test
Fuel Pump / Tank Assembly Replacement
Fuel Pressure Regulator
Fuel Filter
Fuel Injector
Crankshaft Position Sensor (cps)
Manifold Air Pressure Sensor (map)
Operation Overview
Map Sensor Test
Map Sensor Replacement
Intake Air Temperature Sensor (iat)
Operation Overview
Intake Air Temperature Sensor Test
Intake Air Temperature Sensor Replacement
Idle Air Control (iac)
Throttle Position Sensor (tps)
Operation Overview
Throttle Position Sensor Test
Throttle Position Sensor Replacement
Throttle Position Sensor (tps) Initialization
Engine Temperature Sensor
Engine Temperature Sensor Test
Engine Temperature Sensor Replacement
Fuel System Troubleshooting
Fuel Starvation / Lean Mixture
EFI Diagnostics Using ‘blink Codes’
Blink Codes – Operation
Troubleshooting Diagrams
EFI Circuit-power On
EFI Circuit – Crank Position Sensor
EFI Circuit-fuel Pump
EFI Circuit – Ignition Coil
EFI Circuit – Idle Air Control
EFI Circuit-throttle Position Sensor
EFI Circuit – Manifold Absolute Pressure Sensor
EFI Circuit – Engine Coolant Temperature
EFI Circuit – Air Temperature Sensor
EFI Circuit – Malfunction Indicator Light

Chapter 5 Body I Steering I Suspension
General Information
Torque Specifications
Special Tools
Decal Replacement
Plastic Insert Removal / Installation
Body
Side Panel Removal
Front Cover Removal / Installation
Foot Well Removal / Installation
X2-touring Foot Well Removal I Installation
Front Storage Removal
Front Storage Installation
Sportsman Rear Rack Removal / Installation
Front Cab/fender Removal/installation
Sportsman Rear Cab / Fender Removal I Installation
X2-touring Rear Quarter Panel Removal / Installation
Sportsman Rear Storage Removal / Installation
Radiator Screen Removal
Sportsman Body Assembly Exploded View
X2-touring Body Assembly Exploded View
Touring Body/rack Assembly Exploded View
Body / Rack Exploded Views
Touring Body/seat Assembly Exploded View
Headlight Pod Exploded View
Steering
Handlebar Block Installation Procedure
Steering / A-arm Exploded View
A-arm Replacement
Ball Joint Replacement
Steering Post Removal
Steering Post Assembly
Suspension
Front Strut Cartridge Replacement
Strut Assembly
Sportsman Rear Suspension Assembly
X2-touring Rear Suspension Exploded View
X2-touring Torsion Bar Exploded View
X2 Cargo Box
Exploded View
Removal / Installation
X2 Seat Assembly
Exploded Views
X2 Seat Operation – Configuring Cargo Box For Passenger Riding
X2 Driver Seat Backrest Removal / Installation
X2 Passenger Seat Backrest Removal / Installation

Chapter 6 Clutch System
Special Tools And Specifications
Special Tools
Service Note
Component Fastener Torques
Pvt Exploded Views
Pvt Sealing And Ducting Components
Drive Clutch Exploded Views
Driven Clutch Exploded Views
Engine Braking System (ebs) Exploded View
Pvt System
Pvt Operation Overview
Drive Clutch Operation
Driven Clutch Operation
Ebs Clutch Operation
Pvt Maintenance / Inspection
Drive Clutch Spring
Optional Shift Weights
Pvt Drying
Pvt Disassembly
Pvt Installation
Drive Belt Removal / Inspection
Drive Belt Installation
Clutch Alignment
Clutch Offset
Ebs Drive Clutch Service
Drive Clutch Disassembly
Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
Drive Clutch Inspection
Moveable Sheave Bushing Inspection
Drive Clutch Bushing Service
One-way Clutch Inspection (drive Clutch)
Drive Clutch Reassembly
Ebs Driven Clutch Service
Driven Clutch Disassembly
Driven Clutch Bushing Removal/installation
Ebs Driven Clutch Reassembly
Standard Drive Clutch – 500 Carburetor
Drive Clutch Disassembly
Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
Sheave / Bushing Inspection
Drive Clutch Bushing Service
Drive Clutch Reassembly
Standard Driven Clutch – 500 Carburetor
Exploded View
Clutch Disassembly/inspection
Bushing Service
Moveable Sheave – Bushing Installation
Clutch Assembly
Pvt Troubleshooting
Overheating
Problem, Cause And Remedy Chart

Chapter 7 Final Drive
Specifications
Torque Table
Special Tools
Gearcase Fluid / Capacity
Front Hub
Disassembly
Assembly
Front Drive Shaft (cv) Service
Removal
Installation
Inspection
Cv Joint/boot Replacement
Prop Shaft – Front
Removal And Installation
U-joint
Disassembly
Assembly
Drive Axle Exploded Views
Drive Shafts And Propshaft
Front Gearcase – Centralized Hilliard
Exploded View
Operation
Gearcase Removal
Disassembly / Inspection
Reassembly / Inspection
Setting Ring Gear Backlash
Front Gearcase Diagnosis
Gearcase Installation
Front Gearcase – Active Descent Control
Adc Gearcase Exploded View
Operation
Adc Coil Testing
Adc Differential Hydraulic Circuit Bleeding
Disassembly / Inspection
Adc Gearcase Piston Replacement Procedure
Assembly
Rear Hub
Removal
Disassembly
Assembly
Installation
Rear Drive (cv) Shaft Service
Removal
Service
Cv Boot Replacement
Installation
Drive Shaft And Cv Joint Handling Tips

Chapter 8 Transmission
Transmission – General
Mounting Exploded View
Torque Specifications
Special Tools
Lubrication
Gear Selector Removal
Transmission Removal
Transmission Installation
Troubleshooting Checklist
Transmission Service
X2 – Touring Exploded View
500 Carbureted Exploded View
Transmission Disassembly
Transmission Assembly
Transmission Output Shaft Backlash Procedure
And Gearcase Reassembly – Standard Sportsman
Transmission Output Shaft Disassembly – Sportsman X2/touring
Transmission Output Shaft Backlash Procedure And Gearcase Reassembly – Sportsman X2/touring

Chapter 9 Brakes
Specifications
Torque Table
Component Service Limits
Brake System Exploded Views
X2, Touring System Component Exploded View
Sportsman System Component Exploded View
Brake Caliper Exploded Views
Sportsman And X2, Touring Front Caliper Assembly
X2 Touring Rear Caliper Assembly
Sportsman Rear Caliper Assembly
Hydraulic Brake System
Operation Overview
Brake Noise Troubleshooting
Brake Bleeding / Fluid Change
Front Master Cylinder
Removal
Installation
Front Brakes
Pad Removal
Assembly
Brake Burnishing Procedure
Front Brake Disc
Inspection
Removal / Replacement
Front Caliper
Removal
Inspection
Reassembly
Installation
Rear Brake Pad
X2 Touring Pad Removal
X2, Touring Pad Installation
Sportsman Rear Pad Removal
Sportsman Rear Pad Installation
Brake Burnishing Procedure
X2, Touring Rear Caliper
Removal
Inspection
Reassembly
Sportsman Rear Caliper
Removal And Inspection
Assembly
Rear Brake Disc
Inspection
Rear Master Cylinder
X2, Touring Exploded View
Overview
X2, Touring Rear Master Cylinder Removal And Installation
Sportsman Rear Master Cylinder Removal / Installation
Pedal Removal And Installation
Troubleshooting

Chapter 10 Electrical
General Information
Special Tools
Ignition System / Basic Electrical Components
Electrical Service Notes
Troubleshooting
Power Distribution Module (pdm)
Sportsman 500 Carbureted Overview
Instrument Cluster
Overview
Instrument Cluster Diagnostic Mode
Setting A New Service Interval
EFI Diagnostic Mode
Speedometer Removal
Speedometer Installation
All Wheel Drive And Speedometer Troubleshooting
Test 1 – No All Wheel Drive
Test 2 – No Speedometer Display
Test 3 – No Reverse Speed Limit
Test 4 – No Awd Hub Safety Limit
Test 5 – Reverse Speed Limiter Activated In Forward Gear
Test 6-wheel Speed Sensor
Test 7 – Fuel Gauge Display Not Working
Test 8 – Shift Indicator Not Working
Active Descent Control (adc) Coil
Operation Overview – EFI Only
Diagnosing System Failures
All Wheel Drive (awd) Coil
Operation Overview
Diagnosing System Failures
Cooling System Components
Fan Control Circuit Operation
Fan Control Bypass Test
Fan Motor Current Draw Test
Coolant Temperature Sensor
Gear Position Indicator Switch
Test Diagram
Electronic Throttle Control (etc) Switch
Operation Overview
Etc Test
Ignition System
Overview
Components Of Alternator And Dc / Cdi Ignition System
EFI Ignition System Testing Flowchart
Crankshaft Position Sensor Gap
Ignition Troubleshooting
Ignition Output Test Using Gap Tester
Charging System
Current Draw – Key Off
Break Even Test
Alternator Output Test
Charging System Testing Diagrams
Relays
Operation – EFI Models
Fuses/circuit Breaker
Operation – EFI Models
Differential Solenoid
Overview – X2 And Touring
Testing
Replacement
Differential Solenoid Diagram – X2 And Touring
Lighting
High Beam Headlight Bulb Replacement
Headlight Housing Relacement
High Beam Headlight Adjustment
Lower Headlamp Removal / Installation
Low Beam Headlight Adjustment
Headlamp Switch Test
Work Light / Differential Lockout Switch
Brake Light/work Light Replacement
Brake Light Switch Test
Speed Sensor
Testing
Replacement
Fuel Sender
Testing
Accessory Power
Wire Connections
Starter System
Troubleshooting
Voltage Drop Test
Starter Lockout Troubleshooting- EFI Models
Starter Lockout Troubleshooting- Sportsman 500 Carbureted
Starter Lockout Diagram- EFI
Starter Lockout Diagram- Sportsman 500 Carbureted
Starter Motor Removal / Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly
Starter Solenoid Bench Test
Starter Exploded View
Starter Drive
Pinion Gear – Anti-kick Out Shoe, Garter Spring Replacement
Starter System Testing Flowchart
Basic Winch Wiring
Pre-wired Models
Battery
Battery Identification
Battery Activation
Terminal Preparation
Battery Removal
Battery Installation
Off Season Storage
Low Maintenance Battery Off-season Storage
Battery Testing
Conventional Battery Ocv – Open Circuit Voltage Test
Conventional Battery Specific Gravity Test
Battery Load Test
Charging Procedure
Low Maintenance Battery Check:
Low Maintenance Battery Charging
Low Maintenance Battery – Ocv- Open Circuit Voltage Test
Low Maintenance Battery Load Test
Low Maintenance Battery Charging Procedure
Troubleshooting Diagrams
All Wheel Drive-EFI
Fuel Pump And Ignition Coil – EFI
Reverse Override -EFI
Fan Control -EFI

Chapter 11 500 EFI X2 I Touring Quadricycle
500 EFI X2 / Touring Quadricycle Brake System
Overview
Exploded View
500 EFI X2 / Touring Quadricycle Steering Post And Lock
Steering Assembly Exploded View
500 EFI Quadricycle Emissions System
Overview
500 Quadricycle Electrical
Turn / Hazard Signal Diagram

General
Maintenance
Engine
Fuel System
Body / Suspension
Clutch
Transmission
Final Drive
Brakes
Electrical
International
Chapter 1 General Information
Model Number Information
Model Number
Engine Designation Numbers
Vehicle Identification Number (‌VIN)
Transmission ID Location
Engine And Machine Serial Numbers
Publications
Paint Codes
Replacement Keys
2008 Sportsman 500
Model Number: A08mh50ax, Az
2008 Sportsman 500 EFI
Model Number: A08mn50af, An, Aq, As, Ax
2008 Sportsman X-2 500 EFI
Model Number: A08tn50ax, Az / A08tn50ea
2008 Sportsman Touring 500 EFI
Model Number: A08dn50af, As, Az / A08dn50ea
Misc Numbers/charts
Standard Torque Specifications
Sae Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Conversion Table
Glossary Of Terms

Chapter 2 Maintenance
Maintenance
Periodic Maintenance Chart
Maintenance Chart Key
Periodic Maintenance Chart
Lubrication / Fluids
Sportsman Component Locations
Sportsman X2-touring Component Locations
Polaris Lubricants, Maintenance And Service Products
Polaris Lubricant Symbol Identification
Pre-ride / Daily Inspection
Lubrication Components
Front Gearcase Lubrication
Transmission Lubrication
Adc Differential Hydraulic Circuit Fluid Change
Vehicle Inspection
Shift Link Rod Inspection
Throttle Inspection
Throttle Cable / Electronic Throttle Control Adjustment
Fuel System
Fuel Lines
Vent Lines
Fuel Filter
Choke (enricher) Adjustment – (500 Carb)
Compression Test
Engine Mounts
Spark Plug
Active Descent Control (adc) Reservoir Level
Battery Maintenance
Liquid Cooling System Overview
Coolant Strength / Type
Cooling System Hoses
Radiator/grill Screen
Cooling System Pressure Test
Coolant Level Inspection
Radiator Coolant Level Inspection
Air Filter/pre-filter Service
Air Box Sediment Tube
Breather Filter Inspection
Breather Hose
Recoil Housing
Engine Oil Level
Oil And Filter Change
Oil Pump Priming Procedure
Valve Clearance
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Steering
Tie Rod End/steering Inspection
Camber And Caster
Wheel Alignment
Toe Alignment Adjustment
Exhaust Pipe
Brake System Inspection
Brake Pad Inspection
Hose/fitting Inspection
Auxiliary Brake Testing
Auxiliary Brake Adjustment (hydraulic)
Suspension Spring Preload Adjustment
Front Suspension
Cv Shaft Boot Inspection
Controls
Wheels
Wheel, Hub, And Spindle Torque Table
Wheel Removal Front Or Rear
Wheel Installation
Tire Pressure
Tire Inspection
Frame, Nuts, Bolts, Fasteners
Storage Compartments
Winch Operation (if Equipped)
Atv Cleaning & Storage
Sportsman 500 Carbureted Maintenence
Choke (enricher) Adjustment
Pilot Screw
Pilot Screw Adjustment
Idle Speed Adjustment
Fuel Filter
Carburetor Draining
Maintenance Schedule

Chapter 3 Engine
Specifications
Torque Specifications
Special Tools
Engine Fastener Torque Patterns
Engine Service Data
Engine Service Data
General Engine Service
Piston Identification
Cooling System Specifications
Cooling System
Accessible Components
Engine Removal (typical)
Engine Installation Notes
Cylinder Hone Selection/honing Procedure
Honing To Oversize
Cleaning The Cylinder After Honing
Crankshaft Straightening
Engine Lubrication- Eh 50pl
Oil Pressure Test – Eh 50pl
Oil Pump Priming Procedure
Oil Flow-eh50pl
Eh50pl Oil Flow Diagram
Eh50pl Engine Exploded Views
Engine Disassembly
Cam Chain Tensioner/rocker Arm/ Camshaft Removal
Cam Chain Tensioner Inspection
Rocker Arm/shaft Inspection
Camshaft Removal
Automatic Compression Release Removal/inspection
Automatic Compression Release Installation
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Exploded View, Eh50pl
Cylinder Head Inspection
Cylinder Head Warp
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Clearance Adjustment
Cylinder/piston Removal And Inspection
Piston Removal
Cylinder Inspection
Piston-to-cylinder Clearance
Piston/rod Inspection
Piston Ring Installed Gap
Crankcase Disassembly
Starter Drive Removal/inspection
Flywheel/stator Removal/inspection
Cam Chain/tensioner Blade
One Way Valve Removal
Crankcase Separation
Oil Pump Removal/inspection
Oil Pump Assembly
Counter Balancer Shaft Removal/inspection
Crankshaft Removal/inspection
Crankcase Bearing Inspection
Pump Shaft Oil Seal/water Pump Mechanical Seal Removal
Crankcase Inspection
Bearing Installation
End Play Inspection/adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
Engine Reassembly
Pump Shaft Oil Seal Installation
Crankshaft/counter Balance/oil Pump Installation
Crankcase Assembly
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal – Engine Installed
One Way Valve Installation
Cam Chain Drive Sprocket Installation
Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head Installation
Cam Chain/camshaft Installation
Camshaft Timing
Camshaft Timing
Cam Chain Tensioner Installation
Stator, Flywheel And Starter Drive Installation
Rocker Shaft/rocker Arm Assembly Installation
Thermostat Installation
Oil Pipes
Recoil
Recoil Disassembly/inspection
Recoil Assembly
Troubleshooting
Spark Plug Fouling
Engine
Cooling System

Chapter 4 Fuel Injection
Special Tools
Part Numbers / Descriptions
EFI Service Notes
EFI System Exploded View
EFI System
Component Locations/identification
Fuel Tank
Exploded View
Electronic Fuel Injection
EFI Operation Overview
Initial Priming / Starting Procedure
Fuel Lines
Quick Connect Removal/installation
Electronic Control Unit (ecu)
Operation Overview
Ecu Replacement
Ecu Service
Fuel Pump Assembly
Operation/testing
Fuel Pump Test
Fuel Pump / Tank Assembly Replacement
Fuel Pressure Regulator
Fuel Filter
Fuel Injector
Crankshaft Position Sensor (cps)
Manifold Air Pressure Sensor (map)
Operation Overview
Map Sensor Test
Map Sensor Replacement
Intake Air Temperature Sensor (iat)
Operation Overview
Intake Air Temperature Sensor Test
Intake Air Temperature Sensor Replacement
Idle Air Control (iac)
Throttle Position Sensor (tps)
Operation Overview
Throttle Position Sensor Test
Throttle Position Sensor Replacement
Throttle Position Sensor (tps) Initialization
Engine Temperature Sensor
Engine Temperature Sensor Test
Engine Temperature Sensor Replacement
Fuel System Troubleshooting
Fuel Starvation / Lean Mixture
EFI Diagnostics Using ‘blink Codes’
Blink Codes – Operation
Troubleshooting Diagrams
EFI Circuit-power On
EFI Circuit – Crank Position Sensor
EFI Circuit-fuel Pump
EFI Circuit – Ignition Coil
EFI Circuit – Idle Air Control
EFI Circuit-throttle Position Sensor
EFI Circuit – Manifold Absolute Pressure Sensor
EFI Circuit – Engine Coolant Temperature
EFI Circuit – Air Temperature Sensor
EFI Circuit – Malfunction Indicator Light

Chapter 5 Body I Steering I Suspension
General Information
Torque Specifications
Special Tools
Decal Replacement
Plastic Insert Removal / Installation
Body
Side Panel Removal
Front Cover Removal / Installation
Foot Well Removal / Installation
X2-touring Foot Well Removal I Installation
Front Storage Removal
Front Storage Installation
Sportsman Rear Rack Removal / Installation
Front Cab/fender Removal/installation
Sportsman Rear Cab / Fender Removal I Installation
X2-touring Rear Quarter Panel Removal / Installation
Sportsman Rear Storage Removal / Installation
Radiator Screen Removal
Sportsman Body Assembly Exploded View
X2-touring Body Assembly Exploded View
Touring Body/rack Assembly Exploded View
Body / Rack Exploded Views
Touring Body/seat Assembly Exploded View
Headlight Pod Exploded View
Steering
Handlebar Block Installation Procedure
Steering / A-arm Exploded View
A-arm Replacement
Ball Joint Replacement
Steering Post Removal
Steering Post Assembly
Suspension
Front Strut Cartridge Replacement
Strut Assembly
Sportsman Rear Suspension Assembly
X2-touring Rear Suspension Exploded View
X2-touring Torsion Bar Exploded View
X2 Cargo Box
Exploded View
Removal / Installation
X2 Seat Assembly
Exploded Views
X2 Seat Operation – Configuring Cargo Box For Passenger Riding
X2 Driver Seat Backrest Removal / Installation
X2 Passenger Seat Backrest Removal / Installation

Chapter 6 Clutch System
Special Tools And Specifications
Special Tools
Service Note
Component Fastener Torques
Pvt Exploded Views
Pvt Sealing And Ducting Components
Drive Clutch Exploded Views
Driven Clutch Exploded Views
Engine Braking System (ebs) Exploded View
Pvt System
Pvt Operation Overview
Drive Clutch Operation
Driven Clutch Operation
Ebs Clutch Operation
Pvt Maintenance / Inspection
Drive Clutch Spring
Optional Shift Weights
Pvt Drying
Pvt Disassembly
Pvt Installation
Drive Belt Removal / Inspection
Drive Belt Installation
Clutch Alignment
Clutch Offset
Ebs Drive Clutch Service
Drive Clutch Disassembly
Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
Drive Clutch Inspection
Moveable Sheave Bushing Inspection
Drive Clutch Bushing Service
One-way Clutch Inspection (drive Clutch)
Drive Clutch Reassembly
Ebs Driven Clutch Service
Driven Clutch Disassembly
Driven Clutch Bushing Removal/installation
Ebs Driven Clutch Reassembly
Standard Drive Clutch – 500 Carburetor
Drive Clutch Disassembly
Spider Removal
Button To Tower Clearance Inspection
Shift Weight Inspection
Sheave / Bushing Inspection
Drive Clutch Bushing Service
Drive Clutch Reassembly
Standard Driven Clutch – 500 Carburetor
Exploded View
Clutch Disassembly/inspection
Bushing Service
Moveable Sheave – Bushing Installation
Clutch Assembly
Pvt Troubleshooting
Overheating
Problem, Cause And Remedy Chart

Chapter 7 Final Drive
Specifications
Torque Table
Special Tools
Gearcase Fluid / Capacity
Front Hub
Disassembly
Assembly
Front Drive Shaft (cv) Service
Removal
Installation
Inspection
Cv Joint/boot Replacement
Prop Shaft – Front
Removal And Installation
U-joint
Disassembly
Assembly
Drive Axle Exploded Views
Drive Shafts And Propshaft
Front Gearcase – Centralized Hilliard
Exploded View
Operation
Gearcase Removal
Disassembly / Inspection
Reassembly / Inspection
Setting Ring Gear Backlash
Front Gearcase Diagnosis
Gearcase Installation
Front Gearcase – Active Descent Control
Adc Gearcase Exploded View
Operation
Adc Coil Testing
Adc Differential Hydraulic Circuit Bleeding
Disassembly / Inspection
Adc Gearcase Piston Replacement Procedure
Assembly
Rear Hub
Removal
Disassembly
Assembly
Installation
Rear Drive (cv) Shaft Service
Removal
Service
Cv Boot Replacement
Installation
Drive Shaft And Cv Joint Handling Tips

Chapter 8 Transmission
Transmission – General
Mounting Exploded View
Torque Specifications
Special Tools
Lubrication
Gear Selector Removal
Transmission Removal
Transmission Installation
Troubleshooting Checklist
Transmission Service
X2 – Touring Exploded View
500 Carbureted Exploded View
Transmission Disassembly
Transmission Assembly
Transmission Output Shaft Backlash Procedure
And Gearcase Reassembly – Standard Sportsman
Transmission Output Shaft Disassembly – Sportsman X2/touring
Transmission Output Shaft Backlash Procedure And Gearcase Reassembly – Sportsman X2/touring

Chapter 9 Brakes
Specifications
Torque Table
Component Service Limits
Brake System Exploded Views
X2, Touring System Component Exploded View
Sportsman System Component Exploded View
Brake Caliper Exploded Views
Sportsman And X2, Touring Front Caliper Assembly
X2 Touring Rear Caliper Assembly
Sportsman Rear Caliper Assembly
Hydraulic Brake System
Operation Overview
Brake Noise Troubleshooting
Brake Bleeding / Fluid Change
Front Master Cylinder
Removal
Installation
Front Brakes
Pad Removal
Assembly
Brake Burnishing Procedure
Front Brake Disc
Inspection
Removal / Replacement
Front Caliper
Removal
Inspection
Reassembly
Installation
Rear Brake Pad
X2 Touring Pad Removal
X2, Touring Pad Installation
Sportsman Rear Pad Removal
Sportsman Rear Pad Installation
Brake Burnishing Procedure
X2, Touring Rear Caliper
Removal
Inspection
Reassembly
Sportsman Rear Caliper
Removal And Inspection
Assembly
Rear Brake Disc
Inspection
Rear Master Cylinder
X2, Touring Exploded View
Overview
X2, Touring Rear Master Cylinder Removal And Installation
Sportsman Rear Master Cylinder Removal / Installation
Pedal Removal And Installation
Troubleshooting

Chapter 10 Electrical
General Information
Special Tools
Ignition System / Basic Electrical Components
Electrical Service Notes
Troubleshooting
Power Distribution Module (pdm)
Sportsman 500 Carbureted Overview
Instrument Cluster
Overview
Instrument Cluster Diagnostic Mode
Setting A New Service Interval
EFI Diagnostic Mode
Speedometer Removal
Speedometer Installation
All Wheel Drive And Speedometer Troubleshooting
Test 1 – No All Wheel Drive
Test 2 – No Speedometer Display
Test 3 – No Reverse Speed Limit
Test 4 – No Awd Hub Safety Limit
Test 5 – Reverse Speed Limiter Activated In Forward Gear
Test 6-wheel Speed Sensor
Test 7 – Fuel Gauge Display Not Working
Test 8 – Shift Indicator Not Working
Active Descent Control (adc) Coil
Operation Overview – EFI Only
Diagnosing System Failures
All Wheel Drive (awd) Coil
Operation Overview
Diagnosing System Failures
Cooling System Components
Fan Control Circuit Operation
Fan Control Bypass Test
Fan Motor Current Draw Test
Coolant Temperature Sensor
Gear Position Indicator Switch
Test Diagram
Electronic Throttle Control (etc) Switch
Operation Overview
Etc Test
Ignition System
Overview
Components Of Alternator And Dc / Cdi Ignition System
EFI Ignition System Testing Flowchart
Crankshaft Position Sensor Gap
Ignition Troubleshooting
Ignition Output Test Using Gap Tester
Charging System
Current Draw – Key Off
Break Even Test
Alternator Output Test
Charging System Testing Diagrams
Relays
Operation – EFI Models
Fuses/circuit Breaker
Operation – EFI Models
Differential Solenoid
Overview – X2 And Touring
Testing
Replacement
Differential Solenoid Diagram – X2 And Touring
Lighting
High Beam Headlight Bulb Replacement
Headlight Housing Relacement
High Beam Headlight Adjustment
Lower Headlamp Removal / Installation
Low Beam Headlight Adjustment
Headlamp Switch Test
Work Light / Differential Lockout Switch
Brake Light/work Light Replacement
Brake Light Switch Test
Speed Sensor
Testing
Replacement
Fuel Sender
Testing
Accessory Power
Wire Connections
Starter System
Troubleshooting
Voltage Drop Test
Starter Lockout Troubleshooting- EFI Models
Starter Lockout Troubleshooting- Sportsman 500 Carbureted
Starter Lockout Diagram- EFI
Starter Lockout Diagram- Sportsman 500 Carbureted
Starter Motor Removal / Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly
Starter Solenoid Bench Test
Starter Exploded View
Starter Drive
Pinion Gear – Anti-kick Out Shoe, Garter Spring Replacement
Starter System Testing Flowchart
Basic Winch Wiring
Pre-wired Models
Battery
Battery Identification
Battery Activation
Terminal Preparation
Battery Removal
Battery Installation
Off Season Storage
Low Maintenance Battery Off-season Storage
Battery Testing
Conventional Battery Ocv – Open Circuit Voltage Test
Conventional Battery Specific Gravity Test
Battery Load Test
Charging Procedure
Low Maintenance Battery Check:
Low Maintenance Battery Charging
Low Maintenance Battery – Ocv- Open Circuit Voltage Test
Low Maintenance Battery Load Test
Low Maintenance Battery Charging Procedure
Troubleshooting Diagrams
All Wheel Drive-EFI
Fuel Pump And Ignition Coil – EFI
Reverse Override -EFI
Fan Control -EFI

Chapter 11 500 EFI X2 I Touring Quadricycle
500 EFI X2 / Touring Quadricycle Brake System
Overview
Exploded View
500 EFI X2 / Touring Quadricycle Steering Post And Lock
Steering Assembly Exploded View
500 EFI Quadricycle Emissions System
Overview
500 Quadricycle Electrical
Turn / Hazard Signal Diagram