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...
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.