Polaris 800 Touring Sportsman 2008 Workshop Service Manual
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 Touring Year: 2008 Vehicle Type: ATV (All-Terrain Vehicle) Codes Oem Manual Code: Not specified in provided data 👋 Introduction Market Position Segment: High-performance utility/sport ATV Competitive Analysis Competitors: Can-Am Outlander, Arctic Cat 700, Yamaha Grizzly 700, Suzuki King Quad 750 Key Features Versatility: Designed for a blend of recreational riding, utility work, and trail performance. Powertrain Emphasis: Focus on the powerful 800cc V-twin engine and robust drivetrain. Manual Purpose Target Audience: Primarily for mechanical technicians, but valuable for experienced ATV owners. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Page Count Estimated Pages: Typically 400-600 pages for a full workshop manual, specific count not provided. Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drive axles, differential Chassis: Frame, suspension (front and rear), steering, wheels, tires Electrical: Ignition system, charging system, starting system, lighting, instrumentation, accessories Fuel: Fuel tank, fuel pump, fuel injection system (EFI), fuel filter Cooling: Radiator, fan, coolant system Brakes: Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads Body: Body panels, fenders, racks, seat, handlebars Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, spark plug replacement, air filter cleaning/replacement, coolant checks Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable) Disassembly Assembly: Step-by-step instructions for component removal and reinstallation Repair Rebuild: Detailed instructions for repairing or rebuilding major components (engine, transmission, etc.) Specifications Data: Torque specifications, clearances, tolerances, fluid capacities, electrical diagrams Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Quality: High-resolution, designed for clear viewing and printing of diagrams and text. Binding Type Binding: Not applicable (PDF Download) Paper Type Paper Type: Not applicable (PDF Download) Searchability Text Search: Typically searchable text within the PDF document. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, V-twin Displacement: 799 cc (48.8 cubic inches) Bore X Stroke: 89 mm x 64.5 mm Cooling System: Liquid-cooled Performance Horsepower: Approximately 50-55 HP (estimated, official figures may vary) Torque: Approximately 45-50 ft-lbs (estimated, official figures may vary) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Ignition: CDI (Capacitor Discharge Ignition) Engine Management ECU: Engine Control Unit (ECU) for fuel and ignition timing 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive System: Shaft Drive Gear Selection: High, Low, Neutral, Reverse, Park Optional Transfer Case: 2WD/4WD with Active Descent Control (ADC) and Polaris Variable Assist (PVA) steering, depending on trim/configuration. Features Clutch System: Primary and secondary clutch system for CVT operation Fluid Specifications Cvt Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent Fluid Capacities Cvt Fluid Capacity: Approximately 1.2 L (check manual for exact) 📐 Dimensions Exterior Length: 217.2 cm (85.5 inches) Width: 116.8 cm (46 inches) Height: 115.6 cm (45.5 inches) Wheelbase: 133.4 cm (52.5 inches) Ground Clearance: 27.9 cm (11 inches) Cargo Front Rack Capacity: 136 kg (300 lbs) Rear Rack Capacity: 272 kg (600 lbs) Weights Dry Weight: 290 kg (640 lbs) Towing Capacity: 680 kg (1,500 lbs) Tires Front Tire Size: AT 25 x 8-12 Rear Tire Size: AT 25 x 11-12 🛡️ Safety Features Ratings Atv Safety Standards: Meets ANSI standards for recreational off-highway vehicles. (Note: ATVs are not designed for on-road use.) Active Features Braking System: Hydraulic disc brakes (front and rear) Engine Braking: Integrated engine braking via CVT Suspension System: Independent Front Suspension (IFS) and Polaris Independent Rear Suspension (IRS) for improved stability and ride comfort. Passive Features Seat Belt Requirements: Not applicable for this type of ATV; rider must wear a helmet and appropriate safety gear. Lighting Headlights: Dual halogen headlights Taillights: LED taillight and brake light 💡 Technology Features Infotainment Instrumentation: Digital instrument cluster displaying speed, RPM, fuel level, odometer, trip meter, 2WD/4WD indicator, gear indicator, etc. Driver Assistance Assist Systems: Active Descent Control (ADC) for downhill control. Connectivity Charging Port: 12V accessory outlet for charging devices (check for model specifics). 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or annually, whichever comes first. (Refer to manual for exact interval) Air Filter Cleaning: Every 25 hours or more frequently in dusty conditions. Spark Plug Replacement: Recommended every 2 years or 100 hours. (Check manual for specific plug and gap) Belt Inspection: Inspect CVT belt at 50 hours for wear and damage. Replace as needed. Fluid Specifications Engine Oil Type: SAE 0W-40 Synthetic (Polaris recommends their brand, but industry standards can be used if specified) Coolant Type: Ethylene Glycol based antifreeze (50/50 mix with distilled water) Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid Fluid Capacities Engine Oil Capacity: 2.4 L (2.5 US qt) with filter change. (Check manual for exact) Known Issues Cvt Belt Wear: CVT belts can wear...
2WD/4WD with Active Descent Control (ADC) and Polaris Variable Assist (PVA) steering, depending on trim/configuration.
Features
Clutch System:
Primary and secondary clutch system for CVT operation
Fluid Specifications
Cvt Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent
Fluid Capacities
Cvt Fluid Capacity:
Approximately 1.2 L (check manual for exact)
📐 Dimensions
Exterior
Length:
217.2 cm (85.5 inches)
Width:
116.8 cm (46 inches)
Height:
115.6 cm (45.5 inches)
Wheelbase:
133.4 cm (52.5 inches)
Ground Clearance:
27.9 cm (11 inches)
Cargo
Front Rack Capacity:
136 kg (300 lbs)
Rear Rack Capacity:
272 kg (600 lbs)
Weights
Dry Weight:
290 kg (640 lbs)
Towing Capacity:
680 kg (1,500 lbs)
Tires
Front Tire Size:
AT 25 x 8-12
Rear Tire Size:
AT 25 x 11-12
🛡️ Safety Features
Ratings
Atv Safety Standards:
Meets ANSI standards for recreational off-highway vehicles. (Note: ATVs are not designed for on-road use.)
Active Features
Braking System:
Hydraulic disc brakes (front and rear)
Engine Braking:
Integrated engine braking via CVT
Suspension System:
Independent Front Suspension (IFS) and Polaris Independent Rear Suspension (IRS) for improved stability and ride comfort.
Passive Features
Seat Belt Requirements:
Not applicable for this type of ATV; rider must wear a helmet and appropriate safety gear.
Lighting
Headlights:
Dual halogen headlights
Taillights:
LED taillight and brake light
💡 Technology Features
Infotainment
Instrumentation:
Digital instrument cluster displaying speed, RPM, fuel level, odometer, trip meter, 2WD/4WD indicator, gear indicator, etc.
Driver Assistance
Assist Systems:
Active Descent Control (ADC) for downhill control.
Connectivity
Charging Port:
12V accessory outlet for charging devices (check for model specifics).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or annually, whichever comes first. (Refer to manual for exact interval)
Air Filter Cleaning:
Every 25 hours or more frequently in dusty conditions.
Spark Plug Replacement:
Recommended every 2 years or 100 hours. (Check manual for specific plug and gap)
Belt Inspection:
Inspect CVT belt at 50 hours for wear and damage. Replace as needed.
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris recommends their brand, but industry standards can be used if specified)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Fluid Capacities
Engine Oil Capacity:
2.4 L (2.5 US qt) with filter change. (Check manual for exact)
Known Issues
Cvt Belt Wear:
CVT belts can wear and fail prematurely if subjected to excessive heat, overloading, or improper belt tension. Regular inspection is crucial.
Cooling Fan Failure:
Cooling fan motors can sometimes fail, leading to overheating. Check fan operation regularly.
Efi Sensor Issues:
EFI system sensors (e.g., TPS, MAP) can occasionally cause performance issues if they fail or become contaminated.
Suspension Component Wear:
Bushings and ball joints in the suspension can wear over time, leading to play and handling degradation.
📚 Vehicle History
Brand Heritage
Polarís History:
Polaris Inc. is a long-standing American manufacturer of powersports vehicles, known for its ATVs, snowmobiles, and motorcycles. Founded in 1954.
Model Evolution
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from basic utility models to more performance-oriented and feature-rich versions like the 800 Touring.
Production
Manufacturing Location:
USA (typically Polaris manufacturing facilities)
Production Years:
The 800 Sportsman platform was in production for several years, with the 2008 model representing a specific iteration.
🏆 Awards & Recognition
Recognitions
Atv Awards:
Specific awards for the 2008 Sportsman 800 Touring are not readily available, but Polaris ATVs have consistently received positive reviews and accolades for performance and innovation within the powersports industry.