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2009 Polaris Sportsman 800 EFI ATV Service Repair Workshop Manual Download PDF

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI Model Variant: ATV Year: 2009 Codes Product Id: 2009-Polaris-Sportsman-800-EFI-ATV-Service-Repair-Workshop-Manual-Download-PDF 👋 Introduction Market Position Category: High-performance utility ATV Target Audience: Outdoor enthusiasts, hunters, farmers, recreational riders requiring robust performance and off-road capability. Competitive Analysis Key Competitors: Can-Am Outlander, Arctic Cat 700/1000, Yamaha Grizzly, Kawasaki Brute Force. Key Features Engine Size: 800cc V-twin engine Efi System: Electronic Fuel Injection for improved throttle response and fuel efficiency. Suspension Type: Independent front and rear suspension for superior ride quality and handling. AWD System: On-Demand All-Wheel Drive for enhanced traction. Towing Capacity: Significant towing and rack capacity, typical for utility ATVs of this class. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: Downloadable PDF Page Count Page Count: Varies by specific factory release, typically 300+ pages for this model year and type. 📖 Manual Coverage Systems Covered Engine Service: Complete overhaul, disassembly, assembly, tuning, diagnostics, component testing. Fuel System: EFI system, fuel pump, injectors, pressure regulator, throttle body, fuel tank, lines. Ignition System: CDI unit, ignition coils, spark plugs, wiring. Cooling System: Radiator, fan, thermostat, coolant hoses, water pump. Exhaust System: Muffler, pipes, catalytic converter (if applicable), heat shields. Transmission And Drivetrain: PVT (Polaris Variable Transmission) belt, clutches (primary and secondary), gear case, drive shafts, differentials, AWD system. Brakes: Hydraulic disc brakes (front and rear), master cylinders, calipers, brake lines, pads, rotor specifications. Suspension: Front and rear independent suspension, shocks, springs, A-arms, bushings, alignment specifications. Steering: Handlebar, steering post, tie rods, ball joints, steering rack (if applicable). Electrical System: Battery, charging system (stator, voltage regulator), lighting (headlights, taillights, brake lights), starter motor, wiring diagrams, fuses, relays. Body And Chassis: Frame, body panels, racks, seat, plastics, decals. Diagnostic Troubleshooting: Fault codes, diagnostic procedures, symptom-based troubleshooting. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), belt inspection. Component Overhaul: Engine rebuilds, transmission repairs, suspension component replacement, brake system servicing. Troubleshooting Guides: Step-by-step diagnostics for common and uncommon issues. Electrical Diagnostics: Wiring diagram interpretation, voltage/resistance testing, component testing. Suspension And Steering Alignment: Adjustment procedures and specifications. Technical Depth Depth Level: Comprehensive factory-level detail for professional technicians and advanced DIYers. Diagnostic Tools: Information on necessary special tools and diagnostic equipment (e.g., digital multimeter, pressure gauges). Torque Specifications: Precise torque values for all critical fasteners. Clearances And Tolerances: Specific measurement values for engine components, bearings, etc. Wiring Diagrams: Detailed and color-coded electrical schematics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchable Text: Yes, typically includes searchable text for easy navigation. Print Quality Image Resolution: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, V-Twin, Liquid-Cooled Displacement: 760cc (approximate) Bore X Stroke: Refer to manual for specific factory bore and stroke dimensions. Compression Ratio: Refer to manual for specific factory compression ratio. Performance Horsepower: Estimated 50-55 HP (typical for the class, manual will provide exact figures). Torque: Refer to manual for specific torque figures. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane minimum Fuel Tank Capacity: Typically around 3.25-4.0 gallons (manual will confirm). 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Gear Selection: High, Low, Neutral, Reverse, Park Optional Optional Features: N/A for this specific model's core transmission. Features Clutch System: Adjustable primary and secondary clutches for optimal power delivery. Final Drive: Shaft drive, with AWD engagement 📐 Dimensions Exterior Length: Approx. 83 in. (manual will provide exact dimensions). Width: Approx. 46 in. (manual will provide exact dimensions). Height: Approx. 45 in. (manual will provide exact dimensions). Cargo Front Rack Capacity: Approx. 50 lbs. Rear Rack Capacity: Approx. 100 lbs. Weights Dry Weight: Approx. 600-620 lbs. (manual will provide exact weight). Towing Capacity: Typically 1,500 lbs. (manual will confirm). Gcvw: Gross Combined Vehicle Weight rating, refer to manual. 🛡️ Safety Features Ratings Rollover Testing: ATVs are not typically rated by NHTSA for rollover resistance in the same way as cars. This manual focuses on safe operation and maintenance. Active Features All Wheel Drive: On-Demand AWD system enhances traction and control in challenging terrain. Braking System: Powerful hydraulic disc brakes on all wheels for reliable stopping power. Passive Features Hand Grips And Levers: Ergonomically designed for secure control. Footwells: Designed for rider foot security. 💡 Technology Features Infotainment Instrument Cluster: Digital gauge cluster displaying speed, RPM, fuel level, trip meters, gear indicator, AWD status, and diagnostic codes. Driver Assistance Variable Transmission: PVT system automatically adjusts gear ratios for optimal engine performance under varying loads and speeds. Automatic Headlights: Headlights typically activate automatically with the engine. Connectivity Diagnostic Ports: Onboard diagnostic system with accessible ports for reading fault codes (requires specific tools detailed in manual). 🔧 Maintenance...
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Sku: 41206
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2009 Polaris Sportsman 800 EFI ATV Service Repair Workshop Manual Download PDF2009 Polaris Sportsman 800 EFI ATV Service Repair Workshop Manual Download PDF2009 Polaris Sportsman 800 EFI ATV Service Repair Workshop Manual Download PDF2009 Polaris Sportsman 800 EFI ATV Service Repair Workshop Manual Download PDF
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 800 EFI
Model Variant:
ATV
Year:
2009
Codes
Product Id:
2009-Polaris-Sportsman-800-EFI-ATV-Service-Repair-Workshop-Manual-Download-PDF
👋 Introduction
Market Position
Category:
High-performance utility ATV
Target Audience:
Outdoor enthusiasts, hunters, farmers, recreational riders requiring robust performance and off-road capability.
Competitive Analysis
Key Competitors:
Can-Am Outlander, Arctic Cat 700/1000, Yamaha Grizzly, Kawasaki Brute Force.
Key Features
Engine Size:
800cc V-twin engine
Efi System:
Electronic Fuel Injection for improved throttle response and fuel efficiency.
Suspension Type:
Independent front and rear suspension for superior ride quality and handling.
AWD System:
On-Demand All-Wheel Drive for enhanced traction.
Towing Capacity:
Significant towing and rack capacity, typical for utility ATVs of this class.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
Downloadable PDF
Page Count
Page Count:
Varies by specific factory release, typically 300+ pages for this model year and type.
📖 Manual Coverage
Systems Covered
Engine Service:
Complete overhaul, disassembly, assembly, tuning, diagnostics, component testing.
Fuel System:
EFI system, fuel pump, injectors, pressure regulator, throttle body, fuel tank, lines.
Ignition System:
CDI unit, ignition coils, spark plugs, wiring.
Cooling System:
Radiator, fan, thermostat, coolant hoses, water pump.
Exhaust System:
Muffler, pipes, catalytic converter (if applicable), heat shields.
Transmission And Drivetrain:
PVT (Polaris Variable Transmission) belt, clutches (primary and secondary), gear case, drive shafts, differentials, AWD system.
Brakes:
Hydraulic disc brakes (front and rear), master cylinders, calipers, brake lines, pads, rotor specifications.
Suspension:
Front and rear independent suspension, shocks, springs, A-arms, bushings, alignment specifications.
Steering:
Handlebar, steering post, tie rods, ball joints, steering rack (if applicable).
Electrical System:
Battery, charging system (stator, voltage regulator), lighting (headlights, taillights, brake lights), starter motor, wiring diagrams, fuses, relays.
Body And Chassis:
Frame, body panels, racks, seat, plastics, decals.
Diagnostic Troubleshooting:
Fault codes, diagnostic procedures, symptom-based troubleshooting.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), belt inspection.
Component Overhaul:
Engine rebuilds, transmission repairs, suspension component replacement, brake system servicing.
Troubleshooting Guides:
Step-by-step diagnostics for common and uncommon issues.
Electrical Diagnostics:
Wiring diagram interpretation, voltage/resistance testing, component testing.
Suspension And Steering Alignment:
Adjustment procedures and specifications.
Technical Depth
Depth Level:
Comprehensive factory-level detail for professional technicians and advanced DIYers.
Diagnostic Tools:
Information on necessary special tools and diagnostic equipment (e.g., digital multimeter, pressure gauges).
Torque Specifications:
Precise torque values for all critical fasteners.
Clearances And Tolerances:
Specific measurement values for engine components, bearings, etc.
Wiring Diagrams:
Detailed and color-coded electrical schematics.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable Text:
Yes, typically includes searchable text for easy navigation.
Print Quality
Image Resolution:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, V-Twin, Liquid-Cooled
Displacement:
760cc (approximate)
Bore X Stroke:
Refer to manual for specific factory bore and stroke dimensions.
Compression Ratio:
Refer to manual for specific factory compression ratio.
Performance
Horsepower:
Estimated 50-55 HP (typical for the class, manual will provide exact figures).
Torque:
Refer to manual for specific torque figures.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Tank Capacity:
Typically around 3.25-4.0 gallons (manual will confirm).
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT)
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Optional Features:
N/A for this specific model's core transmission.
Features
Clutch System:
Adjustable primary and secondary clutches for optimal power delivery.
Final Drive:
Shaft drive, with AWD engagement
📐 Dimensions
Exterior
Length:
Approx. 83 in. (manual will provide exact dimensions).
Width:
Approx. 46 in. (manual will provide exact dimensions).
Height:
Approx. 45 in. (manual will provide exact dimensions).
Cargo
Front Rack Capacity:
Approx. 50 lbs.
Rear Rack Capacity:
Approx. 100 lbs.
Weights
Dry Weight:
Approx. 600-620 lbs. (manual will provide exact weight).
Towing Capacity:
Typically 1,500 lbs. (manual will confirm).
Gcvw:
Gross Combined Vehicle Weight rating, refer to manual.
🛡️ Safety Features
Ratings
Rollover Testing:
ATVs are not typically rated by NHTSA for rollover resistance in the same way as cars. This manual focuses on safe operation and maintenance.
Active Features
All Wheel Drive:
On-Demand AWD system enhances traction and control in challenging terrain.
Braking System:
Powerful hydraulic disc brakes on all wheels for reliable stopping power.
Passive Features
Hand Grips And Levers:
Ergonomically designed for secure control.
Footwells:
Designed for rider foot security.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital gauge cluster displaying speed, RPM, fuel level, trip meters, gear indicator, AWD status, and diagnostic codes.
Driver Assistance
Variable Transmission:
PVT system automatically adjusts gear ratios for optimal engine performance under varying loads and speeds.
Automatic Headlights:
Headlights typically activate automatically with the engine.
Connectivity
Diagnostic Ports:
Onboard diagnostic system with accessible ports for reading fault codes (requires specific tools detailed in manual).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or annually, whichever comes first. (Refer to manual for precise intervals).
Transmission Oil Change:
Refer to manual for specific transmission fluid change intervals.
Air Filter Cleaning:
Frequent checks and cleaning, especially in dusty conditions. Replacement as needed.
Spark Plug Replacement:
Refer to manual for recommended spark plug replacement intervals and types.
Fluid Specifications
Engine Oil Type:
Polaris recommends specific synthetic or semi-synthetic engine oils. Refer to manual for viscosity grade (e.g., 0W-40, 5W-50) and API service classification.
Engine Oil Capacity:
Refer to manual for exact oil capacity with and without filter change.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Polaris coolant type.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Gearcase Oil:
Refer to manual for specific gearcase oil viscosity and type (e.g., SAE 80W-90 GL-5).
Known Issues
Clutch Wear:
As with many ATVs, clutch wear can occur with heavy use, potentially leading to reduced performance. Manual covers clutch inspection and adjustment.
Suspension Bushings:
Bushings can wear over time, affecting handling. Manual provides replacement procedures.
Efi System Cleaning:
Periodic cleaning of throttle body and injectors may be beneficial. Manual details these procedures.
📚 Vehicle History
Brand Heritage
Polarid Legacy:
Polaris Industries, a long-standing American manufacturer known for snowmobiles and ATVs.
Model Evolution
Sportsman Lineup:
The Sportsman line has a reputation for durability and utility, with the 800cc engine being a popular choice for power and versatility.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Polaris Sportsman line has consistently received positive reviews for its utility, power, and off-road capability from automotive and powersports publications.
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