POLARIS SPORTSMAN 800 TOURING 2008 Full Service Manual
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 Touring Year: 2008 Generation Generation Code: PWC-11 Codes Vin Prefix: 4XX 👋 Introduction Market Position Market Position: The 2008 Polaris Sportsman 800 Touring was positioned as a premium, long-distance touring ATV, offering enhanced comfort and utility for two riders. It competed in the high-displacement, multi-purpose ATV segment. Competitive Analysis Competitive Analysis: Competitors included models like the Can-Am Outlander MAX, Arctic Cat Thundercat, and Yamaha Grizzly 700. The Sportsman 800 Touring distinguished itself with its comfortable two-up seating, independent rear suspension (IRS), and Polaris's signature AWD system. Key Features Key Features: 800cc V-twin engine, 2-up seating capacity, Polaris Variable Transmission (PVT) with engine braking, On-Demand True All-Wheel Drive, Independent Rear Suspension (IRS), electronic power steering (on some trims), integrated cargo racks. Target Audience Target Audience: Riders seeking a comfortable and capable ATV for trail riding, long-distance excursions, utility work, and two-up adventures. 📋 Manual Details Coverage Areas Coverage Areas: Complete service, maintenance, and troubleshooting for 2008 Polaris Sportsman 800 Touring Page Count Page Count: Estimated 500+ pages (based on typical comprehensive service manuals for this type of vehicle) Manual Type Manual Type: Professional Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Engine, Fuel System, Drivetrain (AWD/2WD), Transmission (CVT), Suspension, Steering, Brakes, Electrical System (Wiring Diagrams, Ignition, Charging), Cooling System, Exhaust System, Chassis, Bodywork, Accessories Accessories Coverage: Wiring and installation guides for common accessories like winches, auxiliary lighting, and hand warmers. Procedures Included Procedures Included: Scheduled Maintenance, Engine Overhaul, Transmission Service, Suspension Adjustment, Brake Bleeding and Repair, Electrical Diagnostics, Carburetor/EFI Tuning, Cooling System Flush, Troubleshooting Fault Codes, Component Replacement, Lubrication Procedures Troubleshooting Procedures: Detailed diagnostic flowcharts for common issues (starting problems, overheating, electrical faults, drivetrain noises). Technical Depth Technical Depth: Comprehensive: From basic fluid changes and filter replacements to complete engine teardowns, transmission rebuilds, and advanced electrical system diagnostics. Includes detailed torque specifications and repair procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans with clear diagrams and text, suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, 8-valve, SOHC, 90° V-twin, liquid-cooled Engine Displacement: 775 cc (47.3 cu. in.) Bore X Stroke: 83 mm x 71.5 mm Compression Ratio: 9.0:1 Engine Cooling: Liquid-cooled with fan Performance Horsepower: Approximately 50-55 hp (estimated at peak) Torque: Approximately 48-50 lb-ft (estimated) Fuel System Fuel Delivery: Fuel Injection (EFI) - Bosch system Fuel Type: Unleaded gasoline, 87 octane minimum Fuel Capacity: 4.0 US gal (15.1 L) with 0.8 US gal (3.0 L) reserve Lubrication System Oil Pump Type: Wet sump with pressure lubrication Ignition System Ignition Type: Electronic Ignition (CDI/Digital) Engine Features Starter System: Electric Starter with Recoil Backup (if applicable) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: On-Demand True All-Wheel Drive (AWD) / 2WD Final Drive: Shaft Drive Transmission Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent (refer to manual for specific PN) Transmission Fluid Capacity: Refer to manual (typically ~10-12 oz) Clutch Primary Clutch: Polaris P85 Primary Clutch Secondary Clutch: Polaris 2075446 Sportsman/Ranger Secondary Clutch 📐 Dimensions Exterior Length: 85.2 in (2164 mm) Width: 46 in (1168 mm) Height: 47.5 in (1207 mm) Wheelbase: 56.25 in (1429 mm) Ground Clearance: 11.25 in (286 mm) Tire Size Front: AT 25 x 8-12 Tire Size Rear: AT 25 x 10-12 Wheel Type: Steel or Aluminum Alloy (depending on trim) Wheel Bolt Pattern: 4x110 Cargo Front Rack Capacity: 100 lb (45 kg) Rear Rack Capacity: 200 lb (90 kg) Weights Dry Weight: 693 lb (314 kg) Towing Capacity: 1,750 lb (793.8 kg) Gcvw: 2,443 lb (1108 kg) 🛡️ Safety Features Ratings Safety Ratings: N/A (ATVs typically do not receive NHTSA or IIHS crash ratings like passenger vehicles) Active Features Active Features: Hydraulic Disc Brakes (front and rear), Engine Braking (PVT), On-Demand AWD Passive Features Passive Features: Anti-kickback steering, handlebar handguards, integrated floorboards with heel guards, seatbelts (if equipped with aftermarket roll cage/seating), operator presence system. 💡 Technology Features Infotainment Infotainment System: Basic analog/digital instrument cluster displaying speedometer, odometer, trip meter, fuel level, RPM, gear indicator, AWD status, and warning lights. No integrated infotainment or audio systems typically. Driver Assistance Driver Assistance Features: Electronic Power Steering (EPS) available on some trims for reduced steering effort. Engine braking via PVT. Connectivity Connectivity Features: Accessory power outlets (12V). No integrated Bluetooth or smartphone connectivity. Lighting Lighting System: Dual 50W halogen headlights, LED tail/brake lights. 🔧 Maintenance Service Intervals Initial Service: First service at 10 hours or 1 month (oil change, filter inspection, chain adjustment, bolt torque check). Regular Service Interval: Every 100 hours or 6 months (engine oil and...
The 2008 Polaris Sportsman 800 Touring was positioned as a premium, long-distance touring ATV, offering enhanced comfort and utility for two riders. It competed in the high-displacement, multi-purpose ATV segment.
Competitive Analysis
Competitive Analysis:
Competitors included models like the Can-Am Outlander MAX, Arctic Cat Thundercat, and Yamaha Grizzly 700. The Sportsman 800 Touring distinguished itself with its comfortable two-up seating, independent rear suspension (IRS), and Polaris's signature AWD system.
Key Features
Key Features:
800cc V-twin engine, 2-up seating capacity, Polaris Variable Transmission (PVT) with engine braking, On-Demand True All-Wheel Drive, Independent Rear Suspension (IRS), electronic power steering (on some trims), integrated cargo racks.
Target Audience
Target Audience:
Riders seeking a comfortable and capable ATV for trail riding, long-distance excursions, utility work, and two-up adventures.
📋 Manual Details
Coverage Areas
Coverage Areas:
Complete service, maintenance, and troubleshooting for 2008 Polaris Sportsman 800 Touring
Page Count
Page Count:
Estimated 500+ pages (based on typical comprehensive service manuals for this type of vehicle)
Detailed diagnostic flowcharts for common issues (starting problems, overheating, electrical faults, drivetrain noises).
Technical Depth
Technical Depth:
Comprehensive: From basic fluid changes and filter replacements to complete engine teardowns, transmission rebuilds, and advanced electrical system diagnostics. Includes detailed torque specifications and repair procedures.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans with clear diagrams and text, suitable for printing.
Anti-kickback steering, handlebar handguards, integrated floorboards with heel guards, seatbelts (if equipped with aftermarket roll cage/seating), operator presence system.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog/digital instrument cluster displaying speedometer, odometer, trip meter, fuel level, RPM, gear indicator, AWD status, and warning lights. No integrated infotainment or audio systems typically.
Driver Assistance
Driver Assistance Features:
Electronic Power Steering (EPS) available on some trims for reduced steering effort. Engine braking via PVT.
Connectivity
Connectivity Features:
Accessory power outlets (12V). No integrated Bluetooth or smartphone connectivity.
Lighting
Lighting System:
Dual 50W halogen headlights, LED tail/brake lights.
🔧 Maintenance
Service Intervals
Initial Service:
First service at 10 hours or 1 month (oil change, filter inspection, chain adjustment, bolt torque check).
Regular Service Interval:
Every 100 hours or 6 months (engine oil and filter change, check all fluids, inspect brakes, adjust cables, check tire pressure, inspect belt).
Major Service Interval:
Refer to manual for specific intervals (e.g., spark plug replacement, valve adjustment, coolant flush, transmission service).
Fluid Specifications
Engine Oil Type:
Polaris PS-4 Full Synthetic 5W-50 (or equivalent API SG or higher, JASO MA certified)
Engine Oil Capacity:
Refer to manual (typically around 2.5-3 quarts)
Coolant Type:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water. Polaris recommended: Polaris Premium Pre-Mixed Antifreeze/Coolant (PN 2877883)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Grease Type:
Lithium complex grease, NLGI #2
Known Issues
Known Issues:
CV joint boot tears, occasional starter solenoid issues, potential for CVT belt wear if overloaded or ridden aggressively, cooling system leaks (hoses/radiator), exhaust system corrosion.
Part Numbers
Engine Oil Filter Pn:
Polaris 3082624 (or equivalent)
Air Filter Pn:
Polaris 2540086 (or equivalent)
Spark Plug Pn:
NGK CR7E or similar (verify with manual)
Suspension Maintenance
Grease Points:
Front and rear suspension components (ball joints, tie rods, pivot points) require regular greasing.
Brake Maintenance
Brake Pad Replacement Interval:
Inspect every 6 months or 50 hours; replace as needed based on wear.
Cooling System Maintenance
Coolant Flush Interval:
Every 2 years or 100 hours.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Polaris has a long-standing history in powersports, dating back to snowmobiles in the 1950s. They entered the ATV market in the 1980s and have been a dominant force, known for innovation and performance.
Model Evolution
Model Evolution:
The Sportsman line has been a cornerstone for Polaris. The 800cc engine platform, introduced in earlier models, was refined for performance and touring capabilities. The 'Touring' designation specifically highlighted the two-up riding experience with improved seating and passenger comfort features.
Production
Production Years For Model Variant:
The 800 engine was produced in various Sportsman configurations for many years. The 'Touring' variant was specifically developed to cater to the growing demand for recreational, two-up ATVs.
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