Polaris 800 Touring Sportsman 2009 2010 Service Manual
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 Touring Model Variant: 800 Touring Years Covered: 2009, 2010 Codes Vin Decoder Notes: VIN decoder information typically found in manuals for chassis identification, not explicitly detailed in product description. 👋 Introduction Market Position Vehicle Segment: High-performance All-Terrain Vehicle (ATV) with a touring capability, designed for utility, recreation, and long-distance trail riding. Competitive Analysis Competitors 2009 2010: Can-Am Outlander, Arctic Cat Thundercat, Yamaha Grizzly, Honda Foreman/Rancher, Kawasaki Brute Force. Key Features Touring Comfort: Ergonomic seating for two, passenger backrest and handholds, independent rear suspension (IRS) for improved ride quality on varied terrain. Powertrain Performance: Powerful V-twin engine, capable of handling demanding trails, towing, and recreational use. Manual Value Proposition Value For Mechanics: Empowers mechanical technicians with detailed procedures, specifications, and troubleshooting to perform accurate and efficient repairs. Value For Owners: Enables knowledgeable owners to perform routine maintenance, minor repairs, and understand complex systems, saving on service costs. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhauls Page Count Estimated Page Count: Extensive (typical for workshop manuals, often 500+ pages, exact count not specified in product info) Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, internal components, cooling system, lubrication system, fuel delivery, ignition system, starting system, exhaust system, emissions controls. Drivetrain Systems: Transmission, final drive, driveshafts, CV joints, differential (if applicable), all-wheel drive system (On-Demand AWD operation and servicing). Chassis Systems: Suspension (front and rear), steering system, braking system (hydraulic, calipers, master cylinder, lines), wheels, tires. Electrical Systems: Wiring diagrams, lighting, charging system (alternator/stator, battery), ignition switch, sensors, ECU/ECM, diagnostics, accessory circuits. Body And Frame: Body panels, frame inspection and repair, storage compartments, seat removal and installation, fenders, handlebars, rack systems. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements, spark plug service, air filter service, brake pad replacement, battery maintenance. Repair Procedures: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper servicing, steering linkage repair, electrical component diagnosis and replacement, drive belt replacement. Troubleshooting Diagnostics: Systematic troubleshooting guides for common issues, diagnostic procedures for engine, electrical, and drivetrain faults, reading diagnostic codes. Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed exploded diagrams, torque specifications, and diagnostic flowcharts. Diagnostic Tools: Information on using diagnostic tools and understanding error codes specific to Polaris vehicles of this era. 📊 Manual Specifications File Format File Format: PDF Searchability: Typically searchable text for easy navigation and information retrieval. Print Quality Print Quality: High-resolution digital format, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, 4-stroke, SOHC, 4 valves per cylinder Displacement: 799 cc Bore X Stroke: 90 mm x 62.4 mm Cooling System: Liquid-cooled Ignition: Electronic Ignition (CDI) Performance Horsepower Estimated: Approximately 50-55 HP (exact figures often proprietary or vary by tuning) Torque Estimated: Approximately 45-50 lb-ft (exact figures often proprietary or vary by tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 87 octane Lubrication Oil Type Specification: SAE 5W-50 Synthetic (refer to manual for exact specification, e.g., Polaris Premium 4 Synthetic or equivalent) Oil Capacity With Filter: Approximately 2.5 quarts (refer to manual for exact capacity) 🔧 Transmission Standard Transmission Type: Automatic, PVT (Polaris Variable Transmission) Drive Modes: High, Low, Neutral, Reverse, Park Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Features Clutching: Durable belt drive system, designed for high torque transfer and variable gear ratios. Final Drive Fluid: Hypoid Gear Oil, SAE 80W-90 (API GL-5) or Polaris AGL (refer to manual for exact specification). 📐 Dimensions Exterior Overall Length: Approx. 85.2 inches (2164 mm) Overall Width: Approx. 47.2 inches (1199 mm) Overall Height: Approx. 50.1 inches (1273 mm) Wheelbase: Approx. 56.5 inches (1435 mm) Ground Clearance: Approx. 11.25 inches (286 mm) Weights Dry Weight Estimated: Approx. 690 lbs (313 kg) Towing Capacity: 1500 lbs (680.4 kg) Rack Capacity Front: 300 lbs (136 kg) Rack Capacity Rear: 150 lbs (68 kg) Cargo Cargo Storage: Front and rear rack systems, some models feature lockable storage compartments. 🛡️ Safety Features Ratings Atv Safety Standards: Adherence to ANSI/SVIA standards for ATVs. Active Features Braking System: Hydraulic disc brakes front and rear, often with engine braking assist from the PVT. Drive Assist: On-Demand AWD system automatically engages front wheels when rear wheels lose traction. Passive Features Rollover Protection: N/A (ATV design inherently lacks ROPS unless modified) Lighting: Dual headlights, taillight/brake light. Seatbelts: N/A (ATV design typically uses rider positioning, not seatbelts) 💡 Technology Features Infotainment Infotainment Features: Basic; typically no integrated infotainment system beyond basic instrumentation (speedometer, odometer, fuel gauge, indicator lights). Driver...
Systematic troubleshooting guides for common issues, diagnostic procedures for engine, electrical, and drivetrain faults, reading diagnostic codes.
Technical Depth
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed exploded diagrams, torque specifications, and diagnostic flowcharts.
Diagnostic Tools:
Information on using diagnostic tools and understanding error codes specific to Polaris vehicles of this era.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Typically searchable text for easy navigation and information retrieval.
Print Quality
Print Quality:
High-resolution digital format, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, 4-stroke, SOHC, 4 valves per cylinder
Displacement:
799 cc
Bore X Stroke:
90 mm x 62.4 mm
Cooling System:
Liquid-cooled
Ignition:
Electronic Ignition (CDI)
Performance
Horsepower Estimated:
Approximately 50-55 HP (exact figures often proprietary or vary by tuning)
Torque Estimated:
Approximately 45-50 lb-ft (exact figures often proprietary or vary by tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication
Oil Type Specification:
SAE 5W-50 Synthetic (refer to manual for exact specification, e.g., Polaris Premium 4 Synthetic or equivalent)
Oil Capacity With Filter:
Approximately 2.5 quarts (refer to manual for exact capacity)
🔧 Transmission
Standard
Transmission Type:
Automatic, PVT (Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD)
Features
Clutching:
Durable belt drive system, designed for high torque transfer and variable gear ratios.
Final Drive Fluid:
Hypoid Gear Oil, SAE 80W-90 (API GL-5) or Polaris AGL (refer to manual for exact specification).
📐 Dimensions
Exterior
Overall Length:
Approx. 85.2 inches (2164 mm)
Overall Width:
Approx. 47.2 inches (1199 mm)
Overall Height:
Approx. 50.1 inches (1273 mm)
Wheelbase:
Approx. 56.5 inches (1435 mm)
Ground Clearance:
Approx. 11.25 inches (286 mm)
Weights
Dry Weight Estimated:
Approx. 690 lbs (313 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Rack Capacity Front:
300 lbs (136 kg)
Rack Capacity Rear:
150 lbs (68 kg)
Cargo
Cargo Storage:
Front and rear rack systems, some models feature lockable storage compartments.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Adherence to ANSI/SVIA standards for ATVs.
Active Features
Braking System:
Hydraulic disc brakes front and rear, often with engine braking assist from the PVT.
Drive Assist:
On-Demand AWD system automatically engages front wheels when rear wheels lose traction.
N/A (ATV design typically uses rider positioning, not seatbelts)
💡 Technology Features
Infotainment
Infotainment Features:
Basic; typically no integrated infotainment system beyond basic instrumentation (speedometer, odometer, fuel gauge, indicator lights).
Driver Assistance
Driver Assistance Features:
On-Demand AWD is a primary traction assistance feature. Engine braking via PVT.
Connectivity
Connectivity Features:
N/A (No built-in connectivity options like Bluetooth or USB).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or annually (refer to manual for precise intervals, as usage varies greatly).
Belt Inspection Replacement:
Inspect every 50 hours, replace as needed (wear dependent). Crucial for PVT system performance.
Spark Plug Replacement:
Typically every 100 hours or annually.
Air Filter Cleaning Replacement:
Inspect frequently, clean every 25-50 hours, replace as needed depending on operating conditions.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze/coolant (e.g., Polaris Coolant or equivalent 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Wear Items:
Drive belt, wheel bearings, ball joints, tie rod ends, suspension bushings due to heavy use and terrain.
Electrical Concerns:
Potential for stator or voltage regulator issues in some older Polaris models; water ingress into connectors.
Pvt System Care:
Proper belt tension and alignment are critical. Overheating can shorten belt life. Frequent inspection is recommended.
📚 Vehicle History
Brand Heritage
Polaris Atv Legacy:
Polaris has a long history in powersports, pioneering many features in the ATV market, including independent rear suspension and automatic transmissions.
Model Evolution
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility/recreational ATV series, known for its comfort, capability, and advanced features for its time.
800 Touring Introduction:
The Touring models were introduced to cater to riders who wanted extended comfort and the ability to carry a passenger with ease.
Production
Manufacturing Location:
Primarily USA (Polaris Industries, Medina, MN; manufacturing facilities in Roseau, MN and Spirit Lake, IA are common for Polaris).
🏆 Awards & Recognition
Recognitions
Atv Of The Year Awards:
While specific awards for the 2009-2010 800 Touring model are not readily publicized, the Polaris Sportsman line has consistently received accolades for its overall performance and utility over the years.
Ratings
User Reviews General:
Generally well-regarded for its power, comfort for two-up riding, and off-road capability, although, like many ATVs, subject to wear and tear depending on usage and maintenance.