2009 Polaris Sportman 800 EFI Service Repair Manual Download PDF
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman Touring 800 EFI Year: 2009 Vehicle Type: All-Terrain Vehicle (ATV) Chassis Code: Not explicitly provided, but models are distinct variants of the Sportsman 800 platform. 👋 Introduction Market Position Positioning: The 2009 Polaris Sportsman 800 EFI series represented Polaris's offering in the high-performance, large-displacement utility ATV segment, known for its powerful engine and versatile capabilities. Competitive Analysis Competitors: Competed against models like the Can-Am Outlander 800, Arctic Cat Thundercat 1000, and Yamaha Grizzly 700. Key Features Engine Performance: The 800cc EFI engine provided strong power and torque for hauling, towing, and trail riding. Efi Technology: Electronic Fuel Injection ensured optimal performance in varying altitudes and temperatures, along with easier starting. Versatility: Offered in standard, X2 (two-up seating with cargo box conversion), and Touring (longer wheelbase, two-up comfort) configurations, catering to diverse rider needs. 📋 Manual Details Coverage Areas Primary Coverage: 2009 Polaris Sportsman 800 EFI, 2009 Polaris Sportsman X2 800 EFI, 2009 Polaris Sportsman Touring 800 EFI Engine Coverage: 800 EFI Page Count Estimated Page Count: Comprehensive, no specific page count provided, typical for detailed service manuals. Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine service, including disassembly, assembly, and troubleshooting. Fuel System: Fuel Injection (EFI) system diagnostics, cleaning, and repair. Body Suspension Steering: Body panels, suspension components (shocks, springs, A-arms), steering system, and related hardware. Clutch System: Primary and secondary clutch service, maintenance, and adjustments. Final Drive: Front and rear differential, driveshafts, and hub service. Transmission: Transmission service and repair procedures. Brakes: Brake system maintenance, bleeding, pad replacement, and component repair. Electrical: Complete electrical system diagnostics, wiring diagrams, component testing, and troubleshooting. Wiring Diagrams: Detailed wiring schematics for all electrical systems. International Models: Specific procedures and information for the 800 Touring EFI International variant. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, and general upkeep. Repair: Step-by-step repair instructions for all major components and systems. Disassembly Assembly: Detailed instructions for taking apart and putting back together various vehicle components. Troubleshooting: Diagnostic procedures and fault finding for common and uncommon issues. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: All pages are printable. Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: Not applicable (digital format). Compatibility Operating Systems: Compatible with All Versions of Windows & Mac. Requirements Software Requirements: Adobe PDF Reader. Delivery Delivery Method: Instant Download, No Shipping Cost. ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, 4-stroke, SOHC, 4 valves per cylinder Displacement: 799cc (approximate) Bore X Stroke: 94.25 mm x 74.1 mm (typical for this engine family) Cooling System: Liquid-cooled Ignition: Electronic CDI Performance Horsepower: Approximately 55-60 HP (estimated, exact figures vary by model year and tuning) Torque: Strong mid-range torque, optimized for pulling and hauling. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 87 octane Oil Specifications Engine Oil Type: SAE 20W-50 (refer to manual for specific Polaris recommendations) Engine Oil Capacity: Approximately 3.0 US quarts (2.8 L) with filter change (verify in manual). 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive System: On-Demand AWD / 2WD Features Gear Selection: High, Low, Neutral, Reverse, Park Fluid Type Transmission Oil Type: Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent) Fluid Capacity Transmission Oil Capacity: Refer to manual for specific capacities for front/rear gearcases. 📐 Dimensions Exterior Length: Varies by model: Sportsman (approx. 81 in.), Sportsman X2 (approx. 83 in.), Sportsman Touring (approx. 87 in.) Width: Sportsman/X2: approx. 46 in., Touring: approx. 48 in. Height: Sportsman/X2: approx. 47 in., Touring: approx. 53 in. Weights Dry Weight: Approx. 600-650 lbs (varies by model) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) (Sportsman/Touring), X2 varies with configuration. Wheelbase Wheelbase: Sportsman/X2: 50.5 in., Touring: 56.5 in. Ground Clearance Ground Clearance: 11.5 in. (29.2 cm) 🛡️ Safety Features Ratings Atv Safety: As a utility ATV, emphasis is on stability and control during operation on varied terrain. No formal crash ratings like automobiles. Active Features Braking System: Hydraulic disc brakes front and rear, with engine braking for downhill control. Suspension Type: Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) for optimal ride and handling. Passive Features Operator Protection: Handlebar guards, integrated floorboards for foot protection. 💡 Technology Features Infotainment Display: Digital instrumentation cluster with speedometer, tachometer, odometer, trip meter, and various warning lights. Driver Assistance Engine Braking: The PVT system incorporates engine braking, assisting in controlling speed on descents. Connectivity Charging System: 12V accessory outlet for charging devices (if equipped). 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or 12 months,...
Not explicitly provided, but models are distinct variants of the Sportsman 800 platform.
👋 Introduction
Market Position
Positioning:
The 2009 Polaris Sportsman 800 EFI series represented Polaris's offering in the high-performance, large-displacement utility ATV segment, known for its powerful engine and versatile capabilities.
Competitive Analysis
Competitors:
Competed against models like the Can-Am Outlander 800, Arctic Cat Thundercat 1000, and Yamaha Grizzly 700.
Key Features
Engine Performance:
The 800cc EFI engine provided strong power and torque for hauling, towing, and trail riding.
Efi Technology:
Electronic Fuel Injection ensured optimal performance in varying altitudes and temperatures, along with easier starting.
Versatility:
Offered in standard, X2 (two-up seating with cargo box conversion), and Touring (longer wheelbase, two-up comfort) configurations, catering to diverse rider needs.
Sportsman/X2: approx. 46 in., Touring: approx. 48 in.
Height:
Sportsman/X2: approx. 47 in., Touring: approx. 53 in.
Weights
Dry Weight:
Approx. 600-650 lbs (varies by model)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg) (Sportsman/Touring), X2 varies with configuration.
Wheelbase
Wheelbase:
Sportsman/X2: 50.5 in., Touring: 56.5 in.
Ground Clearance
Ground Clearance:
11.5 in. (29.2 cm)
🛡️ Safety Features
Ratings
Atv Safety:
As a utility ATV, emphasis is on stability and control during operation on varied terrain. No formal crash ratings like automobiles.
Active Features
Braking System:
Hydraulic disc brakes front and rear, with engine braking for downhill control.
Suspension Type:
Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) for optimal ride and handling.
Passive Features
Operator Protection:
Handlebar guards, integrated floorboards for foot protection.
💡 Technology Features
Infotainment
Display:
Digital instrumentation cluster with speedometer, tachometer, odometer, trip meter, and various warning lights.
Driver Assistance
Engine Braking:
The PVT system incorporates engine braking, assisting in controlling speed on descents.
Connectivity
Charging System:
12V accessory outlet for charging devices (if equipped).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or 12 months, whichever comes first (verify in manual).
Air Filter Cleaning:
Inspect and clean every 25 hours or as needed based on conditions; replace as necessary.
Spark Plug Replacement:
Typically every 100-200 hours or as recommended by the manual.
Clutch Maintenance:
Inspect primary and secondary clutches for wear, alignment, and belt condition every 50 hours.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water) suitable for extreme temperatures.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid (verify in manual).
Known Issues
Common Wear Items:
Drive belts, wheel bearings, tie rod ends, and brake pads are common wear items subject to regular inspection and replacement.
Efi Performance Tips:
Keeping the fuel system clean and using fresh fuel is crucial for optimal EFI performance.
📚 Vehicle History
Brand Heritage
Polariss Heritage:
Polaris has a long history in powersports, dating back to snowmobiles, and has been a leading ATV manufacturer for decades, known for innovation in engine technology and suspension.
Model Evolution
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, continuously evolving in engine size, features, and suspension technology. The 800 EFI model was a significant iteration offering substantial power.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Polaris Sportsman models have historically received positive reviews and recognition within the ATV industry for performance and utility.