Download 2009 Polaris Sportsman 800 EFI X2/Touring Repair Manual PDF
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI X2 / Touring Year: 2009 Generation Generation Designation: Polaris Sportsman 4th Generation (2005-2013) Codes Chassis Code: Likely specific Polaris internal codes, not typically published externally for ATVs in a way comparable to automotive chassis codes. 👋 Introduction Market Position Category: High-performance All-Terrain Vehicle (ATV) Target User: Designed for recreational trail riding, utility tasks, and sport riding, appealing to a broad range of ATV enthusiasts. Competitive Analysis Competitors: Can-Am Outlander, Yamaha Grizzly, Arctic Cat Thundercat/Prowler (for utility/sport crossover models). Key Features Engine Power: The 800cc EFI engine provides substantial power for its class, suitable for hauling, towing, and spirited riding. Suspension And Ride: Independent suspension on all four wheels offers improved ground clearance and a smoother ride over varied terrain. Versatility: X2 and Touring variants offer enhanced passenger comfort and cargo-carrying capabilities, expanding the ATV's utility. Efi System: Electronic Fuel Injection ensures optimal performance, fuel efficiency, and easier starting in varying altitudes and temperatures. 📋 Manual Details Coverage Areas Covered Models: 2009 Polaris Sportsman 800 EFI, 2009 Polaris Sportsman X2 800 EFI, 2009 Polaris Sportsman Touring 800 EFI Page Count Estimated Pages: Estimates vary for digital manuals, but typically comprehensive repair manuals of this nature range from 500 to over 1000 pages. Manual Type Type: Factory Authorized Repair Manual / Service Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Powertrain: Engine (800cc V-Twin EFI), Transmission (PVT - Polaris Variable Transmission), Drivetrain (AWD/2WD engagement, differentials, drive shafts) Chassis And Suspension: Frame, front suspension (McPherson strut), rear suspension (independent dual A-arm), steering system, wheels and tires Electrical System: Ignition system, battery, charging system (stator, regulator/rectifier), lighting, fuel injection system (EFI), sensors, ECU, starter motor, instrumentation Bodywork And Ergonomics: Body panels, racks, seat, handlebars, controls, storage Brakes Braking System: Hydraulic disc brakes (front and rear), brake lines, master cylinders, calipers, parking brake Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plugs, valve adjustments, drive belt inspection/replacement), lubrication points, fluid level checks Repair And Overhaul: Engine disassembly, inspection, and reassembly; transmission service; suspension component replacement; steering system repair; brake system overhaul; electrical component testing and replacement Diagnostics And Troubleshooting: Systematic troubleshooting guides, diagnostic procedures for EFI system, electrical fault finding, common issue diagnosis Assembly And Installation: Detailed step-by-step instructions for component removal, cleaning, assembly, and installation with torque specifications Technical Depth Depth Of Coverage: Comprehensive, covering basic to advanced repair and overhaul procedures, including factory-level diagnostics and specifications. 📊 Manual Specifications File Format File Type: PDF Print Quality Resolution And Clarity: High-resolution scans/digital files with clear text, diagrams, and illustrations suitable for printing or on-screen viewing. Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper Quality: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, V-Twin Displacement: 760cc (46.3 cu in) Bore X Stroke: 95 mm x 73.5 mm (3.74 in x 2.89 in) Compression Ratio: 9.5:1 Valve Train: Single Overhead Camshaft (SOHC), 4 valves per cylinder Performance Horsepower: Approx. 50-55 HP (factory quoted figures may vary) Torque: Approximately 52-55 ft-lbs Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with 46mm throttle body Fuel Type: Unleaded gasoline, minimum 87 octane Cooling System Cooling Method: Liquid-cooled with fan 🔧 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) with 2WD option Drive Shafts: Front and rear CV shafts Final Drive: Sealed polygonal chain, sealed eccentric chain 📐 Dimensions Exterior Length: Approx. 83 in (210.8 cm) for standard models, slightly longer for Touring Width: Approx. 46 in (116.8 cm) Height: Approx. 48.5 in (123.2 cm) Wheelbase Wheelbase: Approx. 50.6 in (128.5 cm) Ground Clearance Ground Clearance: Approx. 11.25 in (28.6 cm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Weights Dry Weight: Approx. 650-700 lbs (295-318 kg), varies by model configuration Towing Capacity: 1500 lbs (680 kg) Payload Capacity: 360 lbs (163 kg) 🛡️ Safety Features Ratings Rollover Protection: Not applicable (ATVs do not have the same regulatory safety ratings as passenger vehicles; rider responsibility and protective gear are paramount). Active Features Braking System: Hydraulic disc brakes on all wheels for reliable stopping power. Engine Braking: PVT system provides engine braking for controlled descents. Switchable AWD: On-Demand True AWD provides enhanced traction when needed. Passive Features Integrated Lighting: Headlights, taillights, and brake lights for visibility. Ergonomic Controls: Designed for rider comfort and control. 💡 Technology Features Infotainment Instrumentation: Digital instrumentation cluster typically includes speedometer, odometer, trip meter, fuel gauge, clock, and indicator lights for AWD, engine, and oil. Driver Assistance Traction Control: On-Demand True AWD system provides a form of traction assistance. Connectivity Accessories Power: Often equipped with a DC outlet for charging accessories or powering electronic devices....
Engine disassembly, inspection, and reassembly; transmission service; suspension component replacement; steering system repair; brake system overhaul; electrical component testing and replacement
Diagnostics And Troubleshooting:
Systematic troubleshooting guides, diagnostic procedures for EFI system, electrical fault finding, common issue diagnosis
Assembly And Installation:
Detailed step-by-step instructions for component removal, cleaning, assembly, and installation with torque specifications
Technical Depth
Depth Of Coverage:
Comprehensive, covering basic to advanced repair and overhaul procedures, including factory-level diagnostics and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Resolution And Clarity:
High-resolution scans/digital files with clear text, diagrams, and illustrations suitable for printing or on-screen viewing.
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper Quality:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, SOHC, V-Twin
Displacement:
760cc (46.3 cu in)
Bore X Stroke:
95 mm x 73.5 mm (3.74 in x 2.89 in)
Compression Ratio:
9.5:1
Valve Train:
Single Overhead Camshaft (SOHC), 4 valves per cylinder
Performance
Horsepower:
Approx. 50-55 HP (factory quoted figures may vary)
Torque:
Approximately 52-55 ft-lbs
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with 46mm throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane
Cooling System
Cooling Method:
Liquid-cooled with fan
🔧 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) with 2WD option
Drive Shafts:
Front and rear CV shafts
Final Drive:
Sealed polygonal chain, sealed eccentric chain
📐 Dimensions
Exterior
Length:
Approx. 83 in (210.8 cm) for standard models, slightly longer for Touring
Width:
Approx. 46 in (116.8 cm)
Height:
Approx. 48.5 in (123.2 cm)
Wheelbase
Wheelbase:
Approx. 50.6 in (128.5 cm)
Ground Clearance
Ground Clearance:
Approx. 11.25 in (28.6 cm)
Cargo
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Weights
Dry Weight:
Approx. 650-700 lbs (295-318 kg), varies by model configuration
Towing Capacity:
1500 lbs (680 kg)
Payload Capacity:
360 lbs (163 kg)
🛡️ Safety Features
Ratings
Rollover Protection:
Not applicable (ATVs do not have the same regulatory safety ratings as passenger vehicles; rider responsibility and protective gear are paramount).
Active Features
Braking System:
Hydraulic disc brakes on all wheels for reliable stopping power.
Engine Braking:
PVT system provides engine braking for controlled descents.
Switchable AWD:
On-Demand True AWD provides enhanced traction when needed.
Passive Features
Integrated Lighting:
Headlights, taillights, and brake lights for visibility.
Ergonomic Controls:
Designed for rider comfort and control.
💡 Technology Features
Infotainment
Instrumentation:
Digital instrumentation cluster typically includes speedometer, odometer, trip meter, fuel gauge, clock, and indicator lights for AWD, engine, and oil.
Driver Assistance
Traction Control:
On-Demand True AWD system provides a form of traction assistance.
Connectivity
Accessories Power:
Often equipped with a DC outlet for charging accessories or powering electronic devices.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or 6 months, whichever comes first. (Refer to manual for precise interval).
Air Filter Cleaning:
Inspect every 50 hours or 3 months, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Typically recommended every 100-200 hours or annually. (Refer to manual for exact part number and gap).
Drive Belt Inspection:
Inspect every 50 hours or 6 months for wear and damage. Replace as per manual recommendations or if condition dictates.
Valve Adjustment:
Typically every 100-200 hours or annually. Crucial for maintaining engine performance and longevity.
Fluid Specifications
Engine Oil:
Polaris Synthetic 2W-50 or equivalent API SG or higher oil. Capacity approx. 2.0-2.5 US quarts (1.9-2.4 Liters) with filter. (Refer to manual for exact specification and capacity).
Transmission Fluid:
Polaris Demand Drive Fluid for front differential, Polaris AGL Synthetic Gearcase Lubricant for rear final drive. (Refer to manual for exact specifications and quantities).
Coolant:
Ethylene glycol based antifreeze (50/50 mix with distilled water). Total capacity approx. 2.5 US quarts (2.4 Liters). (Refer to manual for specific type and capacity).
Known Issues
Common Wear Items:
Drive belts, wheel bearings, tie rod ends, ball joints, and brake pads are common wear items on ATVs of this era and usage type.
Efi System Sensitivities:
While generally robust, EFI systems can be sensitive to fuel quality and may require cleaning of injectors or throttle body over time. Troubleshooting guides in the manual are essential.
Suspension Wear:
Aggressive riding or heavy use can accelerate wear on suspension components, requiring regular inspection and potential replacement of bushings, ball joints, and shock absorbers.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles, ATVs, and UTVs since its founding in 1954.
Model Evolution
Sportsman Lineage:
The Sportsman has been a flagship model for Polaris, consistently evolving with new technologies and features, known for its comfort, versatility, and capability.
2009 Updates:
The 2009 models likely continued to refine the 800 EFI platform, building on previous years with potential minor updates in styling, features, or suspension tuning.
Production
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 2009 model year are not readily available in general public databases, but the Sportsman line has historically received accolades for performance, utility, and innovation in the ATV market.
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