Just picked up a 2007 Sportsman 800 EFI X2. It has been sitting in my cousins barn, and he hardly ever used it. It has 100 hours, 1000 miles. It always ran great but 2 minutes after owning it it stated cutting out and dying. Gas smells old, and I found a mouse nest in the air box. I need to get that old gas out asap.

It needs fully serviced, and a good bath. Does anyone have a link to a service manual. I want to give it the full treatment.

Thanks in advance.

 

Easy way to get the gas out is to use a short hose and shop rags around the tank opening. Pressurize the tank slowly with an air nozzle and drain the gas into a gas can. After it's serviced and cleaned up if it still cuts out and dies,the most common problem on these were the tbap connector and wiring that could short. Thin wiring and cheap connectors were the problem. In the expert section read the "sticky" post on 700/800 efi problems about looking for bare or soft feeling wires and the post shows a good place to get better repair kits than Polaris offers.https://otbpowersports.com/products/ Here's good manual for 5 bucks that can help.2007 Polaris Sportsman X2 800 EFI Service Manual PDF Download

 

Thanks OPT, pressurizing the tank worked great. I pulled the schrader valve out and let the pump get the rest of the gas out, there was alot in there.

Biggest thing I noticed was the left plug was slightly leaner than the right.

I did the complete 100 hour service by the book. Only issue I had was confusion on the transmission, the manual said 32 oz in tranny and no rear diff on the x2, and dealer told me they all took seperate rear diff fluid, which I could not find anywhere. The trans and rear diff look like one piece to me. Also the front diff fill plug was kind of a pain to get out, the bumper is smack dab in the way. Swivel worked great.

Anyways, I got all fresh fuel, new plugs, all fluids changed. It was too late tonight to take it out, im hopeful tomorrow it runs great.

 

32 ounces is amount needed when dry from the factory. The manual screws up on this quantity and does confuse people. Should take around 20 ounces or so when drained and refilled. No rear diff,gear case incorporates the rear drive. Front diff fill plugs have always been a pain ever since they went to the hex head style plugs on the side of the diff.

 

Quad is alive and well. More power than I'll ever need, but it sure is fun!

 

Glad it's out of storage and running good. Sitting up hurts them way more than using them on a regular basis.