This manual covers the 2009 Sportsman 800 EFI X2 and Sportsman 800 EFI Touring models. A renowned American manufacturer, has a strong heritage in powersports, and the Sportsman line is recognized for its utility and performance. The 2009 models represent a refined iteration of the successful 800cc EFI platform, with the X2 offering a versatile two-up configuration and dump bed, while the Touring model emphasizes rider comfort for extended use. These ATVs are engineered for a range of applications, from demanding work to recreational trail riding, reflecting a commitment to durability and capability in the off-road segment. This factory service repair manual provides comprehensive, dealership-level technical information for the maintenance and repair of your 2009 Sportsman. It includes detailed procedures for all major systems, including the powertrain, chassis, and electrical systems, along with specific guidance for the 800cc EFI engine and CVT transmission. The manual is designed to assist owners, mechanics, and technicians by offering step-by-step instructions, diagnostic troubleshooting guides, exploded view illustrations, and essential technical specifications. Its scope covers scheduled maintenance, fluid changes, component testing, and in-depth repair instructions, ensuring the optimal performance and longevity of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI X2, Sportsman 800 EFI Touring Year: 2009 Codes Vehicle Platform Code: Not explicitly stated, but likely derived from the 800cc Polaris ATV platform. 👋 Introduction Market Position Positioning: Targets owners and independent repair shops seeking professional-grade documentation for maintenance and repair of the 2009 Polaris Sportsman 800 EFI X2 and Touring models. Positions itself as the definitive resource for these ATVs. Competitive Analysis Analogy: Similar to OEM service manuals provided to authorized dealerships. Offers a significant advantage over generic online guides or basic owner's manuals in terms of technical detail and accuracy. Key Features Features: Step-by-step instructions, clear pictures, exploded view illustrations, schematics, specifications, comprehensive system coverage. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for 2009 Polaris Sportsman 800 EFI X2 and 2009 Polaris Sportsman 800 EFI Touring. Secondary Coverage: May include diagnostic procedures and technical specifications applicable to other closely related Polaris models within the 800cc EFI engine family. Page Count Estimated Page Count: Typically 500-800 pages for comprehensive dealer service manuals of this era and scope. Specific count not provided in product information. Manual Type Type: Factory Service Repair Manual (Dealership Level) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel Injection, Clutch System, Final Drive, Transmission Chassis: Body, Steering, Suspension, Brakes Electrical: Complete electrical system, wiring diagrams Specialty Systems: 800 Touring EFI International (likely specific components or regional variations) Procedures Included Maintenance: Scheduled maintenance, fluid changes, lubrication, inspections Diagnostics: Troubleshooting guides, diagnostic codes (if applicable), component testing Repair: Step-by-step repair instructions for all major systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system service. Disassembly Assembly: Exploded view illustrations detailing component order and torque specifications for reassembly. Technical Depth Depth: Dealership-level technical depth, covering everything from basic adjustments to complete system overhauls and complex diagnostics. Designed for professional mechanics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Quality: High-quality digital reprint of dealer manual. Expect clear text, schematics, and illustrations. Searchable text is a common feature of quality PDF manuals. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 800cc, Liquid-Cooled, 4-Stroke, SOHC, Twin-Cylinder (Engine code typically R12A-XX, specific code not provided in product info) Bore X Stroke: Approximately 80 mm x 79 mm (Typical for this engine family, specific values detailed in manual). Compression Ratio: Typically around 10.0:1 to 10.5:1 (Specific value in manual). Performance Horsepower: Estimated 50-55 HP (Specific dyno figures not usually in service manuals, but power output characteristics are discussed). Torque: Estimated 45-50 lb-ft (Specific torque figures available in manual). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - likely throttle body injection (TBI) or multi-point injection (MPI) depending on exact year and variant. Fuel Type: Unleaded gasoline, 87 octane (or higher, as specified in manual). Fuel Pump Pressure: Specific PSI/kPa values detailed in the manual for diagnostic purposes. Lubrication Oil Type: Polaris PS-4 Synthetic 0W-40 or equivalent (Specific API classification and viscosity to be confirmed in manual). Oil Capacity: Approx. 2.0-2.5 Quarts (5W-30/10W-40 for break-in, then switch to 0W-40 PS-4. Specific capacity in manual). Cooling System Coolant Type: Polaris Premium Long Life Coolant or equivalent (ethylene glycol based, specific mixture ratio detailed). Ignition System Ignition Timing: Electronically controlled, typically not adjustable by user, details on sensor inputs provided. Spark Plugs Spark Plug Type: NGK CR9EK or equivalent (Gap specification in manual). 🔧 Transmission Standard Type: Automatic, Variable Transmission (CVT) with High/Low Range and Reverse. Polaris's 'PVT' (Polaris Variable Transmission). Optional Optional Transmission: N/A (CVT is standard on these models). Features Clutch System: Primary and...
This manual covers the 2009 Sportsman 800 EFI X2 and Sportsman 800 EFI Touring models. A renowned American manufacturer, has a strong heritage in powersports, and the Sportsman line is recognized for its utility and performance. The 2009 models represent a refined iteration of the successful 800cc EFI platform, with the X2 offering a versatile two-up configuration and dump bed, while the Touring model emphasizes rider comfort for extended use. These ATVs are engineered for a range of applications, from demanding work to recreational trail riding, reflecting a commitment to durability and capability in the off-road segment.
This factory service repair manual provides comprehensive, dealership-level technical information for the maintenance and repair of your 2009 Sportsman. It includes detailed procedures for all major systems, including the powertrain, chassis, and electrical systems, along with specific guidance for the 800cc EFI engine and CVT transmission. The manual is designed to assist owners, mechanics, and technicians by offering step-by-step instructions, diagnostic troubleshooting guides, exploded view illustrations, and essential technical specifications. Its scope covers scheduled maintenance, fluid changes, component testing, and in-depth repair instructions, ensuring the optimal performance and longevity of your vehicle.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 800 EFI X2, Sportsman 800 EFI Touring
Year:
2009
Codes
Vehicle Platform Code:
Not explicitly stated, but likely derived from the 800cc Polaris ATV platform.
👋 Introduction
Market Position
Positioning:
Targets owners and independent repair shops seeking professional-grade documentation for maintenance and repair of the 2009 Polaris Sportsman 800 EFI X2 and Touring models. Positions itself as the definitive resource for these ATVs.
Competitive Analysis
Analogy:
Similar to OEM service manuals provided to authorized dealerships. Offers a significant advantage over generic online guides or basic owner's manuals in terms of technical detail and accuracy.
Step-by-step repair instructions for all major systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system service.
Disassembly Assembly:
Exploded view illustrations detailing component order and torque specifications for reassembly.
Technical Depth
Depth:
Dealership-level technical depth, covering everything from basic adjustments to complete system overhauls and complex diagnostics. Designed for professional mechanics.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Quality:
High-quality digital reprint of dealer manual. Expect clear text, schematics, and illustrations. Searchable text is a common feature of quality PDF manuals.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
800cc, Liquid-Cooled, 4-Stroke, SOHC, Twin-Cylinder (Engine code typically R12A-XX, specific code not provided in product info)
Bore X Stroke:
Approximately 80 mm x 79 mm (Typical for this engine family, specific values detailed in manual).
Compression Ratio:
Typically around 10.0:1 to 10.5:1 (Specific value in manual).
Performance
Horsepower:
Estimated 50-55 HP (Specific dyno figures not usually in service manuals, but power output characteristics are discussed).
Torque:
Estimated 45-50 lb-ft (Specific torque figures available in manual).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - likely throttle body injection (TBI) or multi-point injection (MPI) depending on exact year and variant.
Fuel Type:
Unleaded gasoline, 87 octane (or higher, as specified in manual).
Fuel Pump Pressure:
Specific PSI/kPa values detailed in the manual for diagnostic purposes.
Lubrication
Oil Type:
Polaris PS-4 Synthetic 0W-40 or equivalent (Specific API classification and viscosity to be confirmed in manual).
Oil Capacity:
Approx. 2.0-2.5 Quarts (5W-30/10W-40 for break-in, then switch to 0W-40 PS-4. Specific capacity in manual).
Cooling System
Coolant Type:
Polaris Premium Long Life Coolant or equivalent (ethylene glycol based, specific mixture ratio detailed).
Ignition System
Ignition Timing:
Electronically controlled, typically not adjustable by user, details on sensor inputs provided.
Spark Plugs
Spark Plug Type:
NGK CR9EK or equivalent (Gap specification in manual).
🔧 Transmission
Standard
Type:
Automatic, Variable Transmission (CVT) with High/Low Range and Reverse. Polaris's 'PVT' (Polaris Variable Transmission).
Optional
Optional Transmission:
N/A (CVT is standard on these models).
Features
Clutch System:
Primary and Secondary Clutch system, with detailed service and adjustment procedures for belt wear, roller maintenance, and spring/sheave inspection.
Final Drive:
Shaft Drive with sealed, lubricated driveshafts. Gearcase lubricant type and capacity specified in manual.
Fluid Specifications
Cvt Fluid:
Specific CVT fluid or approved alternative with detailed performance characteristics required. Not standard ATF.
Gearcase Fluid:
Polaris Demand Drive Fluid or equivalent (GL-5 gear oil with specific viscosity, details in manual).
📐 Dimensions
Exterior
Wheelbase:
Approx. 50.5 inches for X2, slightly longer for Touring (Specific dimensions in manual).
Overall Length:
Varies between X2 and Touring, detailed in manual.
Overall Width:
Typically around 48 inches (Varies slightly by model, check manual).
Overall Height:
Varies, detailed in manual.
Weights
Dry Weight:
Approx. 645-680 lbs (Depending on specific model variant, detailed in manual).
Ground Clearance:
Approximately 11.5 inches (Check manual for exact specification).
Towing Capacity:
Typically 1500 lbs (Refer to manual for specific rating).
Rack Capacity Front:
Typically 100 lbs (Refer to manual for specific rating).
Rack Capacity Rear:
Typically 200 lbs (Refer to manual for specific rating).
Wheels Tires
Front Tire Size:
25 x 8-12 or 26 x 8-12 (Specifics in manual).
Rear Tire Size:
25 x 10-12 or 26 x 10-12 (Specifics in manual).
Wheel Bolt Pattern:
4/115 mm (common for Polaris ATVs of this era, confirm in manual).
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (ATVs are not typically subjected to standardized crash testing like passenger vehicles).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Specific master cylinder, caliper, and rotor specifications are detailed.
Parking Brake:
Integrated into transmission/drive system, with lever or thumb control. Service procedures detailed.
Emphasis on proper riding techniques, safety gear, and vehicle operation within specified limits is a core aspect of any ATV manual.
💡 Technology Features
Infotainment
Infotainment System:
N/A (ATVs of this era typically do not feature integrated infotainment systems beyond basic digital displays for speed, odometer, and engine alerts).
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance systems like ABS, traction control, etc., are standard on this model).
Connectivity
Connectivity Features:
N/A
Engine Management
Engine Control Unit:
ECU for EFI system. Manual details sensor inputs, outputs, and diagnostic procedures for the ECU and associated sensors (e.g., TPS, MAP, IAT).
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 100 hours of operation or annually, whichever comes first (Specific interval detailed in manual).
Air Filter Cleaning:
Recommended every 25-50 hours or as needed based on operating conditions (Details on cleaning and replacement in manual).
Spark Plug Replacement:
Typically every 100-200 hours or annually (Refer to manual for precise recommendation and gap checks).
Cvt Belt Inspection:
Crucial at regular intervals (e.g., 50-100 hours) for wear and damage, critical for performance and preventing catastrophic failure.
Valve Clearance Check:
Recommended at higher hour intervals (e.g., 200-400 hours) for optimal engine performance and longevity (Specific procedures and clearances in manual).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (Confirm exact specification in manual).
Coolant Capacity:
Approx. 2.5-3.0 Quarts (Refer to manual for exact capacity and bleeding procedure).
Known Issues
Common Problems And Solutions:
While the manual is the definitive source, common issues for this era of ATVs can include starter solenoid failures, fuel pump issues, CVT belt wear, and occasional electrical connector corrosion. The manual provides troubleshooting steps for all these.
📚 Vehicle History
Brand Heritage
Heritage:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles and its expansion into ATVs, UTVs, and motorcycles. They have a reputation for innovation and performance.
Model Evolution
Evolution:
The Sportsman 800 platform has been a workhorse for Polaris. The X2 model introduced a unique 2-up seating configuration with a dump bed, while the Touring model focused on enhanced rider comfort for longer excursions. The 2009 model year represents a refinement of this successful platform, incorporating EFI for improved performance and efficiency.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States (e.g., Roseau, Minnesota; Spirit Lake, Iowa).
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the 2009 Sportsman 800 models are not listed in the product information, but the Sportsman line generally received positive reviews for its utility and performance in the off-road community during its production run.
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