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Polaris ATV 2009-2010 Sportsman 800 EFI X2 800 Repair Manual

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Basic Information Identification Make: Polaris Model: Sportsman 800 EFI X2 Model Variant: X2 Year: 2009-2010 Codes Engine Code Primary: ProStar 760 EFI (often referred to as 800 for marketing) Chassis Code General: Polaris Sportsman X2 Platform Introduction Market Position Market Segment: High-performance utility ATV (All-Terrain Vehicle) Target User: Recreational riders, hunters, farmers, and professionals requiring robust and versatile off-road capability with passenger carrying ability. Competitive Analysis Key Competitors Era: Yamaha Grizzly, Can-Am Outlander, Arctic Cat Prowler, Honda Foreman/Rancher Key Features Vehicle Unique Selling Proposition: The X2 designation typically signifies the 2-up seating capability, making it a versatile option for carrying a passenger, a feature not common on all utility ATVs of this era. Engine Performance Focus: Emphasis on reliable power delivery for towing, hauling, and trail riding. Manual Value Proposition Manual Benefit: Provides authorized, factory-level diagnostic and repair information, crucial for maintaining peak performance and longevity of the complex EFI system and drivetrain. Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Drivetrain (AWD/2WD), Transmission, Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Electrical System, Lighting, Bodywork, Chassis, Plastics, Accessories, Troubleshooting, Maintenance, Specifications, Torque Values, Wiring Diagrams, Lubrication, Specifications Page Count Page Count: 386 Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and repair procedures for the 760cc ProStar EFI engine. Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, pressure regulator, and related components. Ignition System: CDI unit, spark plugs, ignition timing, and related electrical components. Drivetrain And Transmission: Primary and secondary clutch service, belt inspection and replacement, gearbox maintenance, gear selection, AWD system operation and repair, differential maintenance. Suspension And Steering: Front and rear suspension components, shock absorber service, wheel bearing replacement, steering linkage, tie rods, and steering column repair. Braking System: Hydraulic brake system bleeding, caliper service, master cylinder repair, brake pad replacement, rotor inspection. Electrical System: Battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, brake lights), winch wiring, accessory circuits. Procedures Included Diagnostic Procedures: Troubleshooting charts for common problems, diagnostic codes for EFI system, step-by-step diagnostic flowcharts. Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements (oil, air, fuel), spark plug replacement, valve adjustments, lubrication points, clutch maintenance. Repair Procedures: Detailed, step-by-step instructions for virtually every component replacement and repair, including engine rebuilds, transmission overhauls, and suspension component replacement. Disassembly And Assembly: Comprehensive guides for the complete teardown and reassembly of all major vehicle systems. Wiring Diagrams: Detailed electrical wiring schematics for all circuits, aiding in electrical system troubleshooting and repair. Technical Depth Technical Depth: Comprehensive, covering everything from basic fluid checks and adjustments to complete engine and transmission overhauls. Suitable for professional mechanics and advanced DIY enthusiasts. Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing users to quickly find specific information. Print Quality Print Quality: Designed to be printable with clear diagrams and text. Original factory quality. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, V-Twin Displacement: 760cc (commonly marketed as 800cc) Bore X Stroke: 80 mm x 75 mm (typical for this engine family) Cooling System: Liquid-cooled Performance Horsepower Est: Approximately 50-55 HP (varies by specific model year and tune) Torque Est: Approximately 45-50 lb-ft (varies by specific model year and tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher Throttle Body Size: Likely 46mm or 50mm throttle body Lubrication Oil Type: SAE 5W-50 Synthetic 4-stroke engine oil (check manual for exact specification) Oil Capacity: Approx. 2.5-3.0 US quarts (2.4-2.8 L) with filter change (verify in manual) Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive Modes: 2WD / 4WD (On-Demand) Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Features Clutch Type: Dual clutch system (primary and secondary centrifugals) Final Drive: Shaft drive Fluid Specifications Transmission Fluid Type: Polaris PU-90017 Gearcase Lubricant or equivalent (check manual for exact PN and spec) Fluid Capacities Gearcase Oil Capacity: Approx. 0.5 US quarts (0.47 L) (verify in manual) Dimensions Exterior Length: Approx. 83 in (210.8 cm) Width: Approx. 47.5 in (120.7 cm) Height: Approx. 50 in (127 cm) Wheelbase: Approx. 50.5 in (128.3 cm) Ground Clearance: Approx. 11 in (27.9 cm) Weights Dry Weight: Approx. 670 lbs (304 kg) Towing Capacity: 1500 lbs (680.4 kg) Rack Capacity Front: 200 lbs (90.7 kg) Rack Capacity Rear: 400 lbs (181.4 kg) Cargo Cargo Bed Type: Lock & Ride cargo system with tilt bed on X2 model Cargo Volume Est: Significant volume provided by the tilting rear cargo bed. Safety Features Ratings Atv Safety Standards: Adheres to ANSI/SVIA standards for ATVs. Active Features Braking System: Hydraulic...
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Polaris ATV 2009-2010 Sportsman 800 EFI X2 800 Repair Manual
Basic Information
Identification
Make: Polaris
Model: Sportsman 800 EFI X2
Model Variant: X2
Year: 2009-2010
Codes
Engine Code Primary: ProStar 760 EFI (often referred to as 800 for marketing)
Chassis Code General: Polaris Sportsman X2 Platform
Introduction
Market Position
Market Segment: High-performance utility ATV (All-Terrain Vehicle)
Target User: Recreational riders, hunters, farmers, and professionals requiring robust and versatile off-road capability with passenger carrying ability.
Competitive Analysis
Key Competitors Era: Yamaha Grizzly, Can-Am Outlander, Arctic Cat Prowler, Honda Foreman/Rancher
Key Features Vehicle
Unique Selling Proposition: The X2 designation typically signifies the 2-up seating capability, making it a versatile option for carrying a passenger, a feature not common on all utility ATVs of this era.
Engine Performance Focus: Emphasis on reliable power delivery for towing, hauling, and trail riding.
Manual Value Proposition
Manual Benefit: Provides authorized, factory-level diagnostic and repair information, crucial for maintaining peak performance and longevity of the complex EFI system and drivetrain.
Manual Details
Coverage Areas
Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Drivetrain (AWD/2WD), Transmission, Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Electrical System, Lighting, Bodywork, Chassis, Plastics, Accessories, Troubleshooting, Maintenance, Specifications, Torque Values, Wiring Diagrams, Lubrication, Specifications
Page Count
Page Count: 386
Manual Type
Manual Type: Factory Service Manual / Repair Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Engine Mechanical: Full engine disassembly, assembly, inspection, and repair procedures for the 760cc ProStar EFI engine.
Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, pressure regulator, and related components.
Ignition System: CDI unit, spark plugs, ignition timing, and related electrical components.
Drivetrain And Transmission: Primary and secondary clutch service, belt inspection and replacement, gearbox maintenance, gear selection, AWD system operation and repair, differential maintenance.
Suspension And Steering: Front and rear suspension components, shock absorber service, wheel bearing replacement, steering linkage, tie rods, and steering column repair.
Braking System: Hydraulic brake system bleeding, caliper service, master cylinder repair, brake pad replacement, rotor inspection.
Electrical System: Battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, brake lights), winch wiring, accessory circuits.
Procedures Included
Diagnostic Procedures: Troubleshooting charts for common problems, diagnostic codes for EFI system, step-by-step diagnostic flowcharts.
Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements (oil, air, fuel), spark plug replacement, valve adjustments, lubrication points, clutch maintenance.
Repair Procedures: Detailed, step-by-step instructions for virtually every component replacement and repair, including engine rebuilds, transmission overhauls, and suspension component replacement.
Disassembly And Assembly: Comprehensive guides for the complete teardown and reassembly of all major vehicle systems.
Wiring Diagrams: Detailed electrical wiring schematics for all circuits, aiding in electrical system troubleshooting and repair.
Technical Depth
Technical Depth: Comprehensive, covering everything from basic fluid checks and adjustments to complete engine and transmission overhauls. Suitable for professional mechanics and advanced DIY enthusiasts.
Manual Specifications
File Format
File Format: PDF (Portable Document Format)
Searchability: Likely text-searchable, allowing users to quickly find specific information.
Print Quality
Print Quality: Designed to be printable with clear diagrams and text. Original factory quality.
Binding Type
Binding Type: N/A (Digital PDF download)
Paper Type
Paper Type: N/A (Digital PDF download)
Engine Specifications
Primary Engine
Engine Type: 4-stroke, SOHC, V-Twin
Displacement: 760cc (commonly marketed as 800cc)
Bore X Stroke: 80 mm x 75 mm (typical for this engine family)
Cooling System: Liquid-cooled
Performance
Horsepower Est: Approximately 50-55 HP (varies by specific model year and tune)
Torque Est: Approximately 45-50 lb-ft (varies by specific model year and tune)
Fuel System
Fuel Delivery: Electronic Fuel Injection (EFI)
Fuel Type: Unleaded gasoline, 87 octane or higher
Throttle Body Size: Likely 46mm or 50mm throttle body
Lubrication
Oil Type: SAE 5W-50 Synthetic 4-stroke engine oil (check manual for exact specification)
Oil Capacity: Approx. 2.5-3.0 US quarts (2.4-2.8 L) with filter change (verify in manual)
Transmission
Standard
Transmission Type: Automatic (Polaris Variable Transmission - PVT)
Drive Modes: 2WD / 4WD (On-Demand)
Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Features
Clutch Type: Dual clutch system (primary and secondary centrifugals)
Final Drive: Shaft drive
Fluid Specifications
Transmission Fluid Type: Polaris PU-90017 Gearcase Lubricant or equivalent (check manual for exact PN and spec)
Fluid Capacities
Gearcase Oil Capacity: Approx. 0.5 US quarts (0.47 L) (verify in manual)
Dimensions
Exterior
Length: Approx. 83 in (210.8 cm)
Width: Approx. 47.5 in (120.7 cm)
Height: Approx. 50 in (127 cm)
Wheelbase: Approx. 50.5 in (128.3 cm)
Ground Clearance: Approx. 11 in (27.9 cm)
Weights
Dry Weight: Approx. 670 lbs (304 kg)
Towing Capacity: 1500 lbs (680.4 kg)
Rack Capacity Front: 200 lbs (90.7 kg)
Rack Capacity Rear: 400 lbs (181.4 kg)
Cargo
Cargo Bed Type: Lock & Ride cargo system with tilt bed on X2 model
Cargo Volume Est: Significant volume provided by the tilting rear cargo bed.
Safety Features
Ratings
Atv Safety Standards: Adheres to ANSI/SVIA standards for ATVs.
Active Features
Braking System: Hydraulic disc brakes on all wheels.
Drivetrain Selection: On-Demand True All-Wheel Drive (AWD) for enhanced traction.
Passive Features
Handlebars: Ergonomically designed handlebars with padded grip for control and comfort.
Lighting: Dual 50W headlights, 25/60W brake light/taillight.
Technology Features
Infotainment
Instrument Cluster: Digital LCD display showing speedometer, odometer, tripmeter, fuel level, 4WD indicator, engine hour meter, and diagnostic codes.
Driver Assistance
A Arm Design: MacPherson strut front suspension and dual A-arm rear suspension for stable handling.
Connectivity
Accessory Power: Pre-wired accessory connectors and often a DC outlet for charging devices or powering accessories.
Maintenance
Service Intervals
Initial Service: First service typically around 10-hour or 100-mile mark (check manual for specific break-in procedures).
Engine Oil Change: Every 100 hours or 1000 miles, or annually, whichever comes first (verify in manual).
Air Filter Cleaning: Inspect every 50 hours, clean/replace as needed. More frequent in dusty conditions.
Spark Plug Replacement: Typically every 200 hours or 2 years (verify in manual).
Clutch Belt Inspection: Inspect every 50 hours, replace when worn or damaged.
Fluid Specifications
Engine Oil Pn: Polaris PS-4 5W-50 Synthetic (or equivalent API SG, JASO MA rated oil)
Coolant Type: Antifreeze/coolant meeting Polaris specification (typically ethylene glycol based, 50/50 mix with distilled water)
Brake Fluid Type: DOT 4 brake fluid
Known Issues
Common Wear Items: Drive belts, wheel bearings, suspension bushings, brake pads.
Efi System Considerations: While generally reliable, proper maintenance of fuel system components (filters, injectors) is crucial for optimal EFI performance.
Torque Values
Engine Mount Torque: Specific torque values for engine mounts, cylinder heads, and critical fasteners are detailed in the manual.
Wheel Lug Torque: Specific torque value for wheel lug nuts is provided (e.g., 70-80 ft-lbs).
Vehicle History
Brand Heritage
Polarissportsmanship: Polaris has a long-standing reputation for innovation and performance in the powersports industry, particularly with its Sportsman line of ATVs.
Model Evolution
Sportsman Line: The Sportsman line has been a flagship for Polaris, evolving through various engine sizes and configurations, with the X2 variant focusing on utility and passenger comfort.
2009-2010 Updates: These model years represent a mature iteration of the 800cc Sportsman platform, benefiting from previous engineering refinements, including advanced EFI systems and chassis designs.
Production
Manufacturing Location: Polaris vehicles are primarily manufactured in the United States.
Awards & Recognition
Recognitions
Atv Industry Awards: While specific awards for the 2009-2010 Sportsman 800 X2 are not readily available, the Polaris Sportsman line has consistently received accolades for its performance, comfort, and utility features throughout its history.
Ratings
Consumer Satisfaction: Polaris Sportsman models generally enjoy high consumer satisfaction ratings for their durability and capability.
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