Basic Information Identification Make: Polaris Model: Sportsman 800 Touring Year: 2008 Product Type: Factory Service Repair Manual Engine Variant: 800 EFI Introduction Market Position Segment: Premium All-Terrain (ATV) / Utility Recreation Target Audience: Riders seeking a powerful, comfortable, and capable two-up ATV for trail riding, hunting, and general utility tasks. Competitive Analysis Key Competitors: Can-Am Outlander Max, Arctic Cat Thundercat, Yamaha Grizzly 700, Honda Foreman/Rubicon Differentiation: Known for its smooth ride, powerful V-twin engine, and comfortable passenger seating. Key Features Engine: 800cc liquid-cooled V-twin, fuel-injected Seating: Two-up touring configuration with passenger backrest and handgrips Suspension: Independent front and rear suspension with adjustable shocks Drivetrain: On-Demand True All-Wheel Drive (AWD) Utility: Front and rear racks for cargo, towing capacity Manual Details Coverage Areas Primary Coverage: Complete repair and maintenance for 2008 Polaris Sportsman 800 Touring Page Count Estimated Pages: 500+ Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Disassembly, inspection, assembly, repair of engine components (cylinder head, pistons, crankshaft, camshaft, valves, etc.) Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, fuel tank, lines Cooling System: Radiator, fan, coolant pump, thermostat, hoses, fluid checks Exhaust System: Muffler, exhaust pipes, heat shields, gasket replacement Drivetrain: Primary and secondary clutches, belt inspection and replacement, drive shafts, differentials Suspension: Front and rear suspension components, shock absorbers, A-arms, bushings, adjustments Steering: Steering column, tie rods, steering rack, linkage, troubleshooting Brakes: Hydraulic brake system, master cylinders, calipers, brake pads, rotors, bleeding procedure Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, wiring diagrams Body And Frame: Body panel removal/installation, frame inspection, seat, racks, fenders Wheels And Tires: Tire pressure, wheel removal/installation, lug nut torque Troubleshooting: Diagnostic charts for common problems and their solutions Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, air filter cleaning/replacement Component Disassembly: Step-by-step instructions for taking apart major and minor components Component Assembly: Detailed guidance on reassembling components with correct procedures and torque specifications Repair Procedures: Specific repair methods for worn or damaged parts Diagnostic Procedures: Methods for identifying and resolving malfunctions Wiring Diagrams: Complete electrical schematics for fault finding and component identification Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine rebuilds and complex electrical diagnostics Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Clarity: High-resolution images, diagrams, and text for clear readability Reproducibility: Suitable for printing individual pages or the entire document Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Engine Specifications Primary Engine Type: 4-stroke, 8-valve, SOHC, V-Twin, 45° Displacement: 799.8 cc (48.8 cu. in.) Bore X Stroke: 84.5 mm x 71 mm (3.33 in. x 2.80 in.) Cooling: Liquid-cooled Performance Horsepower: Approx. 53 hp @ 6500 RPM (est.) Torque: Approx. 52 ft-lbs @ 5000 RPM (est.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with 44mm throttle body Fuel Type: Unleaded gasoline, 87 octane or higher Ignition Type: Electronic Ignition Transmission Standard Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Gear Selection: H, L, N, R, P Optional Type: N/A Features Clutch System: High-flow, speed-sensing, variable overdrive belt system Dimensions Exterior Length: 85.1 in. (2161.5 mm) Width: 46 in. (1168.4 mm) Height: 53 in. (1346.2 mm) Wheelbase: 56.5 in. (1435 mm) Ground Clearance: 11.25 in. (285.75 mm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Weights Dry Weight: 675 lbs (306 kg) Towing Capacity: 1,750 lbs (793.8 kg) Hitch Type: 2 in. (50 mm) receiver Safety Features Ratings Safety Certification: California EPA approved Active Features Braking: Hydraulic disc brakes, front and rear Drivetrain: On-Demand True AWD for enhanced traction Passive Features Lighting: Dual headlights, taillight/brake light Ergonomics: Comfortable seating position, handgrips for passenger Rollover Protection: N/A (ATVs do not typically have ROPS as standard) Technology Features Infotainment Instrument Cluster: Digital odometer, speedometer, tachometer, fuel gauge, engine hour meter, gear indicator, AWD indicator, hi-temp light, oil light. Driver Assistance Traction Control: On-Demand True AWD system provides enhanced traction. Connectivity Accessories: Pre-wired for accessory installation (lights, winches, etc.) Maintenance Service Intervals Engine Oil Change: Every 100 hours or annually, whichever comes first. Air Filter Cleaning: Every 50 hours or annually, depending on conditions. Spark Plug Inspection: Every 100 hours or annually. Clutch Belt Inspection: Every 50 hours or annually. Fluid Specifications Engine Oil: Polaris Synthetic 2W-50 (or equivalent API SG/SH/SJ rated) - Capacity: 2.4 L (2.5 US qt) Coolant: Ethylene glycol-based antifreeze mixture (50/50 with distilled water) - Capacity: 2.0 L (2.1 US qt) Brake Fluid: DOT 4 Hydraulic Brake Fluid Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant (or equivalent GL-2 / GL-3 SAE 80W-90) Known Issues Clutch Wear: Early belt wear or clutch engagement issues can occur with aggressive use or improper maintenance. Electrical Connectors: Corrosion or loose...