Polaris Sportsman 800 EFI Sportsman X2 800 EFI Sportsman Touring 800 EFI 2009 Workshop Service Repair Manual

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The Polaris Sportsman 800 EFI, including its Sportsman X2 and Sportsman Touring variants, represents a robust and versatile All-Terrain Vehicle (ATV) platform introduced in 2009. Engineered for both demanding utility tasks and recreational riding, this model is distinguished by its powerful liquid-cooled, 4-stroke, 90-degree V-twin engine, delivering approximately 53 horsepower. Key features include a Variable Transmission (PVT) with engine braking, an on-demand All-Wheel Drive system, and independent front and rear suspension (IRS) for enhanced comfort and ground clearance. Its strong independent suspension, coupled with a potent EFI engine, positions the Sportsman 800 EFI as a capable machine for various terrains and applications, from farm work to trail riding. This comprehensive workshop service repair manual is designed to provide detailed guidance for the maintenance and repair of the 2009 Polaris Sportsman 800 EFI, Sportsman X2 800 EFI, and Sportsman Touring 800 EFI. It covers an extensive range of topics, including routine maintenance procedures, detailed troubleshooting guides for common issues, and step-by-step repair instructions for all major systems. Within its pages, you will find critical technical specifications, torque values, wiring diagrams, and information on specialized tools. This manual serves as an essential resource for owners, technicians, and mechanics to ensure the optimal performance, reliability, and longevity of their Polaris Sportsman ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI Sub Model: Sportsman X2 800 EFI, Sportsman Touring 800 EFI Year: 2009 Codes Chassis Code: Not explicitly stated in provided info, but generally associated with Polaris' ATV chassis design. Engine Code: Not explicitly stated in provided info, typically 800cc V-twin for this model. 👋 Introduction Market Position Segment: High-performance utility and recreational ATVs (All-Terrain Vehicles). Target Audience: Enthusiast riders, farm and ranch owners, hunters, and recreational users seeking a powerful and versatile ATV. Competitive Analysis Key Competitors: Can-Am Outlander, Arctic Cat, Yamaha Grizzly, Honda Foreman/Rancher (though Sportsman often positioned slightly higher in displacement/performance). Strengths: Powerful V-twin engine, excellent independent suspension, comfortable ride, versatile chassis suitable for various models (single-seat, two-up, X2). Key Features Engine Type: Liquid-cooled, 4-stroke, SOHC V-twin EFI engine. Transmission Type: Automatic PVT with engine braking. Suspension Type: Independent front and rear suspension (IRS) providing superior ground clearance and ride comfort. 4Wd System: On-demand AWD (All-Wheel Drive) system with 2WD/AWD switching. Braking System: Hydraulic disc brakes on all wheels. Variants: Standard (800 EFI), X2 (convertible seat/cargo box), Touring (two-up seating). 📋 Manual Details Coverage Areas Covered Models: Polaris Sportsman 800 EFI, Polaris Sportsman X2 800 EFI, Polaris Sportsman Touring 800 EFI Covered Years: 2009 Page Count Estimated Page Count: Likely 500+ pages (typical for a comprehensive workshop manual). Manual Type Type: Workshop Service Repair Manual Language Language: English (Assumed based on product name and common industry practice). Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, inspection, assembly, valve adjustments, piston and cylinder details, crankshaft and connecting rod service, oil pump operation. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel filter, fuel pressure regulator, throttle body, idle air control. Ignition System: Ignition coil, spark plugs, ignition control module (ECM), timing, troubleshooting ignition faults. Cooling System: Radiator, cooling fan, thermostat, water pump, coolant types and capacities, flushing and refilling. Exhaust System: Muffler, catalytic converter (if applicable), exhaust pipe inspection and replacement. Transmission: Automatic transmission (PVT - Polaris Variable Transmission), belt inspection and replacement, clutch calibration, gearbox maintenance, lubrication. Drivetrain: Front and rear driveshafts, differentials (front and rear), CV joints, U-joints, lubrication, troubleshooting drive system issues. Suspension: Front and rear suspension components, shock absorbers, A-arms, bushings, ball joints, steering components, wheel alignment. Braking System: Hydraulic disc brakes (front and rear), brake pads, brake fluid type and replacement, bleeding procedures, caliper service. Steering System: Handlebar, steering shaft, tie rods, steering rack, power steering (if equipped), lubrication and adjustment. Electrical System: Battery, charging system (stator, voltage regulator), starter motor, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays. Bodywork And Chassis: Frame inspection, body panels, fenders, racks, seat, storage compartments, graphics, plastics. Instrumentation And Controls: Dashboard, gauges, switches, controls, diagnostic indicators. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug service, chain/belt adjustment (if applicable), lubrication points, tire pressure checks. Troubleshooting: Diagnostic procedures for common starting issues, running problems, electrical faults, braking issues, and drivetrain malfunctions. Includes symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation for all major systems. Overhaul Procedures: Detailed instructions for complete engine, transmission, and differential rebuilds. Wiring Diagrams: Comprehensive electrical system wiring diagrams for component identification and troubleshooting. Specifications And Tolerances: Precise torque specifications, clearances, and measurement tolerances for all mechanical components. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive, covering everything from basic maintenance and fluid checks to full engine and transmission rebuilds, including advanced diagnostics and electrical system repair....

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Tipo: Atv

Proveedor:

SKU: 92268

Colecciones: ALL ATV Powersports

Disponibilidad: En stock

Etiquetas: 2009 ATV Misc Polaris Powersports Sportsman 800 EFI Sportsman Touring 800 EFI Sportsman X2 800 EFI

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 800 EFI

Sub Model:

Sportsman X2 800 EFI, Sportsman Touring 800 EFI

Year:

Codes

Chassis Code:

Not explicitly stated in provided info, but generally associated with Polaris' ATV chassis design.

Engine Code:

Not explicitly stated in provided info, typically 800cc V-twin for this model.

👋 Introduction

Market Position

Segment:

High-performance utility and recreational ATVs (All-Terrain Vehicles).

Target Audience:

Enthusiast riders, farm and ranch owners, hunters, and recreational users seeking a powerful and versatile ATV.

Competitive Analysis

Key Competitors:

Can-Am Outlander, Arctic Cat, Yamaha Grizzly, Honda Foreman/Rancher (though Sportsman often positioned slightly higher in displacement/performance).

Strengths:

Powerful V-twin engine, excellent independent suspension, comfortable ride, versatile chassis suitable for various models (single-seat, two-up, X2).

Key Features

Engine Type:

Liquid-cooled, 4-stroke, SOHC V-twin EFI engine.

Transmission Type:

Automatic PVT with engine braking.

Suspension Type:

Independent front and rear suspension (IRS) providing superior ground clearance and ride comfort.

4Wd System:

On-demand AWD (All-Wheel Drive) system with 2WD/AWD switching.

Braking System:

Hydraulic disc brakes on all wheels.

Variants:

Standard (800 EFI), X2 (convertible seat/cargo box), Touring (two-up seating).

📋 Manual Details

Coverage Areas

Covered Models:

Polaris Sportsman 800 EFI, Polaris Sportsman X2 800 EFI, Polaris Sportsman Touring 800 EFI

Covered Years:

Page Count

Estimated Page Count:

Likely 500+ pages (typical for a comprehensive workshop manual).

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English (Assumed based on product name and common industry practice).

Format

Format:

Downloadable Digital File (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, inspection, assembly, valve adjustments, piston and cylinder details, crankshaft and connecting rod service, oil pump operation.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel filter, fuel pressure regulator, throttle body, idle air control.

Ignition System:

Ignition coil, spark plugs, ignition control module (ECM), timing, troubleshooting ignition faults.

Cooling System:

Radiator, cooling fan, thermostat, water pump, coolant types and capacities, flushing and refilling.

Exhaust System:

Muffler, catalytic converter (if applicable), exhaust pipe inspection and replacement.

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission), belt inspection and replacement, clutch calibration, gearbox maintenance, lubrication.

Drivetrain:

Front and rear driveshafts, differentials (front and rear), CV joints, U-joints, lubrication, troubleshooting drive system issues.

Suspension:

Front and rear suspension components, shock absorbers, A-arms, bushings, ball joints, steering components, wheel alignment.

Braking System:

Hydraulic disc brakes (front and rear), brake pads, brake fluid type and replacement, bleeding procedures, caliper service.

Steering System:

Handlebar, steering shaft, tie rods, steering rack, power steering (if equipped), lubrication and adjustment.

Electrical System:

Battery, charging system (stator, voltage regulator), starter motor, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays.

Bodywork And Chassis:

Frame inspection, body panels, fenders, racks, seat, storage compartments, graphics, plastics.

Instrumentation And Controls:

Dashboard, gauges, switches, controls, diagnostic indicators.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air), spark plug service, chain/belt adjustment (if applicable), lubrication points, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common starting issues, running problems, electrical faults, braking issues, and drivetrain malfunctions. Includes symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and differential rebuilds.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for component identification and troubleshooting.

Specifications And Tolerances:

Precise torque specifications, clearances, and measurement tolerances for all mechanical components.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance and fluid checks to full engine and transmission rebuilds, including advanced diagnostics and electrical system repair.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format) - Assumed standard for digital workshop manuals.

Searchability:

Likely text-searchable, allowing for quick location of specific information within the manual.

Printability:

Printable pages, allowing users to print specific sections or the entire manual as needed.

Print Quality

Quality:

High-resolution digital scans or original manufacturer files, ensuring clarity of diagrams, text, and images.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, 8-valve, SOHC, 90-degree V-twin

Displacement:

760cc (approximate)

Bore X Stroke:

Typically around 90 mm x 59 mm (specific figures may vary slightly, manual will confirm).

Compression Ratio:

Typically around 9.7:1 (manual will confirm).

Performance

Horsepower:

Approx. 53 HP (at flywheel, specific figure from manual).

Torque:

Approx. 48 lb-ft (at flywheel, specific figure from manual).

Fuel System

Induction:

Electronic Fuel Injection (EFI) with twin throttle bodies.

Fuel Type:

Unleaded gasoline, 87 octane or higher recommended.

Lubrication

Oil Type:

Polaris PS-4 5W-50 Synthetic 4-Cycle Engine Oil (or equivalent API SG rated oil with appropriate viscosity).

Oil Capacity:

Approximately 2.1 US quarts (2.0 Liters) with filter change (verify in manual).

Ignition

Spark Plugs:

NGK CR9E or equivalent (confirm in manual).

Ignition Timing:

Electronically controlled by ECM, not adjustable.

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) Automatic

Drive Modes:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive, On-Demand AWD

Features

Engine Braking:

Yes, provides excellent downhill control.

Clutch Type:

Dual centrifugal clutch system with belt drive.

Fluid Specification

Type:

Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 75W-90 GL-4 automotive gear oil).

Fluid Capacity

Capacity:

Approximately 0.5 US quarts (0.47 Liters) for the transmission/gearcase (verify in manual).

📐 Dimensions

Exterior

Length:

Varies by model (e.g., Sportsman 800: ~83 in. / 210.8 cm; Sportsman Touring 800: ~85.2 in. / 216.4 cm). Manual will confirm precise figures.

Width:

Varies by model (e.g., Sportsman 800: ~46 in. / 116.8 cm). Manual will confirm precise figures.

Height:

Varies by model (e.g., Sportsman 800: ~45.5 in. / 115.6 cm). Manual will confirm precise figures.

Wheelbase:

Varies by model (e.g., Sportsman 800: ~50.5 in. / 128.3 cm; Sportsman Touring 800: ~56.5 in. / 143.5 cm). Manual will confirm precise figures.

Ground Clearance:

Typically 11.25 in. (28.6 cm) (verify in manual).

Cargo

Front Rack Capacity:

Typically 50 lbs (22.7 kg) (verify in manual).

Rear Rack Capacity:

Typically 100 lbs (45.4 kg) for Sportsman 800, higher for X2/Touring variants. Manual will confirm.

Weights

Dry Weight:

Varies by model (e.g., Sportsman 800: ~670 lbs / 304 kg). Manual will confirm precise figures.

Gvw Rating:

Not explicitly stated, but total allowable weight (vehicle + rider + cargo) will be in manual.

Towing Capacity:

Typically 1,500 lbs (680 kg) (verify in manual).

Tongue Weight Capacity:

Typically 150 lbs (68 kg) (verify in manual).

🛡️ Safety Features

Ratings

Crash Test Ratings:

ATVs are not typically subjected to NHTSA or IIHS crash test ratings like passenger vehicles.

Active Features

Braking:

Four-wheel hydraulic disc brakes with front and rear levers for independent control.

Engine Braking:

PVT system provides engine braking for controlled descents.

4Wd System:

On-demand AWD provides enhanced traction in slippery conditions.

Passive Features

Lighting:

Dual front headlights, handlebar-mounted work light, and rear brake/taillight.

Ergonomics:

Designed for rider comfort and control, with handguards and padded seating.

Rollover Protection:

N/A (ATVs do not have integral rollover protection structures).

💡 Technology Features

Infotainment

Display Type:

Basic digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, 4WD indicator, and diagnostic lights.

Audio System:

N/A (No factory-installed audio system on this model).

Driver Assistance

Traction Control:

N/A (No electronic traction control systems).

Hill Descent Control:

N/A (Relies on engine braking provided by the PVT).

Connectivity

Bluetooth:

N/A (No integrated GPS).

Efi System

Type:

Closed-loop EFI with oxygen sensors for precise fuel metering and emissions control.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first. Special conditions (e.g., heavy dust) may require more frequent changes. (Verify exact interval in manual).

Air Filter Cleaning:

Clean every 25 hours or monthly. Replace as needed. (Verify in manual).

Spark Plug Service:

Inspect and clean every 100 hours. Replace every 200 hours or annually. (Verify in manual).

Transmission Oil Change:

Every 100 hours or 6 months. (Verify in manual).

Brake Fluid Flush:

Every 12 months or as needed based on inspection. (Verify in manual).

Drive Belt Inspection:

Inspect every 100 hours. Replace as needed based on wear and tear. (Verify in manual).

Fluid Specifications

Engine Oil:

Polaris PS-4 5W-50 Synthetic or equivalent API SG.

Transmission Gearcase Oil:

Polaris AGL Synthetic Gearcase Lubricant or SAE 75W-90 GL-4.

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Coolant Type:

Ethylene Glycol based antifreeze (50/50 mix with distilled water).

Known Issues

Drive Belt Wear:

Like most CVT systems, drive belts can wear and stretch over time, especially under heavy use or aggressive riding. Regular inspection and replacement are key. The manual will detail inspection criteria.

Suspension Bushings:

Rubber suspension bushings can degrade and wear, leading to play and decreased handling precision. The manual will cover inspection and replacement procedures.

Efi Calibration:

While generally robust, EFI systems can sometimes require recalibration or sensor checks if performance issues arise. The manual's diagnostic section will be invaluable here.

Charging System:

Occasional issues with stators or voltage regulators can occur, leading to battery charging problems. The manual provides specific testing procedures for these components.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc. - a long-standing American manufacturer known for recreational vehicles, including snowmobiles and ATVs.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from simpler utility models to advanced, powerful machines. The 800cc engine platform was a significant step up in performance for the brand.

2009 Updates:

The 2009 model year saw refinement of the 800 EFI platform, building on previous iterations with improvements in ergonomics, suspension tuning, and EFI calibration. The X2 and Touring variants offered distinct utility and passenger-carrying capabilities.

Production

Manufacturing Location:

Primarily manufactured in Spirit Lake, Iowa, USA, and Roseau, Minnesota, USA by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2009 model might not be readily available, Polaris Sportsman models have historically received positive reviews for performance, comfort, and utility from off-road publications.

Ratings

Consumer Reviews:

Generally well-regarded for its power and comfortable ride, particularly the IRS. Some common feedback points often relate to belt longevity and occasional electrical component durability under extreme conditions. The manual is crucial for addressing these proactively.