POLARIS SPORTSMAN TOURING 800 EFI Full Service & Repair Manual 2009-2011

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman Touring 800 EFI Model Variant: Touring Engine Type: EFI (Electronic Fuel Injection) Model Years Covered: 2009, 2010, 2011 Codes Chassis Code: Not specified in product info, typically ATV chassis codes are internal to manufacturer. Engine Code: Not specified in product info, typically Polaris engine codes are internal to manufacturer. 👋 Introduction Market Position Vehicle Segment: Performance Utility ATV (All-Terrain Vehicle) Target Audience: Outdoor enthusiasts, hunters, trail riders, farm/ranch users seeking a versatile and powerful ATV with extended range and comfort. Competitive Analysis Key Competitors: Arctic Cat Prowler, Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rincon. Differentiation: Emphasis on touring capability, powerful V-twin engine, advanced independent suspension, and Polaris's proprietary AWD system. Key Features Engine Configuration: 800cc V-twin, liquid-cooled, 4-stroke engine, delivering strong torque and power. Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking, high/low range, reverse. Suspension Type: Dual A-Arm front and rear suspension with Fox or similar premium shocks, offering excellent ground clearance and ride comfort. Drivetrain System: On-Demand, True AWD/2WD with VersaTrac™ for selectable engagement and enhanced traction. Ergonomics Comfort: Dual-seat configuration with passenger backrest and footrests, ergonomic rider controls, power steering (often standard or optional on touring models). 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, Workshop Secondary Coverage: Troubleshooting, Diagnostics, Maintenance, Overhaul Page Count Page Count: Unknown (PDF download format implies variable page count based on display/print settings, but a definitive number is not provided). Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English (assumed based on typical product descriptions for this market) Format Format: PDF Download Licensing Licensing: No Extra Fees, No Expiry Dates 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, overhaul, and reassembly. Includes cylinder head, pistons, connecting rods, crankshaft, valve train, timing components. Engine Fuel System: EFI system diagnosis, fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, lines. Engine Ignition System: Ignition coil, spark plugs, CDI unit, timing control, sensors. Engine Cooling System: Radiator, fan, coolant pump, thermostat, hoses, coolant specifications. Transmission Drive System: CVT (Continuously Variable Transmission) system, drive belts, clutches (primary and secondary), gearcase, fluid specifications, service procedures. Drivetrain: Front and rear drive shafts, differentials, axles, U-joints, wheel hubs, bearing service. Suspension Steering: Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment, steering system, tie rods, steering column, power steering (if equipped). Braking System: Hydraulic brake system, calipers, master cylinder, brake lines, brake pads, rotors, brake fluid specifications, bleeding procedures. Electrical System: Battery, charging system (stator, rectifier/regulator), starter motor, lighting system (headlights, taillights, indicators), wiring diagrams, fuses, relays, switches, instrumentation. Body Chassis: Frame, body panels, plastics, seating, racks, fenders, bumpers, storage compartments. Diagnostics Troubleshooting: Systematic troubleshooting procedures for common and uncommon issues, fault code interpretation (if applicable to EFI system), diagnostic charts. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug service, drive belt inspection/replacement, lubrication points, tire pressure checks, brake inspection. Engine Repair: Top-end rebuilds, bottom-end overhauls, piston ring replacement, valve adjustments, gasket replacement. Transmission Repair: CVT clutch service, drive belt replacement, gearcase maintenance, seal replacement. Suspension Steering Repair: Ball joint replacement, tie rod end replacement, shock absorber replacement, bushing replacement, steering linkage service. Brake System Repair: Brake pad replacement, rotor replacement, brake line replacement, brake caliper service, brake bleeding. Electrical Troubleshooting: Wiring harness repair, component testing (stator, regulator, starter), battery charging system diagnosis. Bodywork Repair: Panel removal and installation, fender repair, rack mounting and repair. Special Tools: Identification and usage of specialized tools required for specific repairs and adjustments. Technical Depth Depth Level: Comprehensive Factory Level Detail Level: Detailed step-by-step instructions with diagrams and illustrations. Diagnostic Capability: Advanced diagnostic procedures for EFI and electrical systems, including component testing and troubleshooting trees. Rebuild Procedures: Full engine and transmission rebuild specifications, including clearances, torque values, and tolerances. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text within the PDF for keywords (common for factory manuals). Print Quality Print Quality: High-resolution, suitable for professional printing. (Implied by 'Professional Manual') Binding Type Binding Type: N/A (Digital download format) Paper Type Paper Type: N/A (Digital download format) ⚙️ Engine Specifications Primary Engine Engine Type: 800cc, 4-stroke, SOHC, V-twin Displacement: 760 cc (46.4 cubic inches) Bore X Stroke: Approximately 90 mm x 59 mm (specifications may vary slightly by exact year/build). Cooling System: Liquid-cooled Valvetrain: SOHC (Single Overhead Camshaft), 4 valves per cylinder Performance Horsepower: Typically around 55-60 HP (actual figures may vary slightly by model year). Torque: Not precisely specified in product data, but the 800cc V-twin is known for strong low-end and mid-range torque, crucial for towing and hauling. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher Fuel Tank Capacity: Typically around 5.25 gallons (19.9 liters). 🔧 Transmission Standard Transmission Type: Automatic...

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Tags: 2009 2010 2011 ATV Misc Polaris Powersports SPORTSMAN TOURING 800 EFI

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Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 800 EFI

Model Variant:

Touring

Engine Type:

EFI (Electronic Fuel Injection)

Model Years Covered:

2009, 2010, 2011

Codes

Chassis Code:

Not specified in product info, typically ATV chassis codes are internal to manufacturer.

Engine Code:

Not specified in product info, typically Polaris engine codes are internal to manufacturer.

👋 Introduction

Market Position

Vehicle Segment:

Performance Utility ATV (All-Terrain Vehicle)

Target Audience:

Outdoor enthusiasts, hunters, trail riders, farm/ranch users seeking a versatile and powerful ATV with extended range and comfort.

Competitive Analysis

Key Competitors:

Arctic Cat Prowler, Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rincon.

Differentiation:

Emphasis on touring capability, powerful V-twin engine, advanced independent suspension, and Polaris's proprietary AWD system.

Key Features

Engine Configuration:

800cc V-twin, liquid-cooled, 4-stroke engine, delivering strong torque and power.

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking, high/low range, reverse.

Suspension Type:

Dual A-Arm front and rear suspension with Fox or similar premium shocks, offering excellent ground clearance and ride comfort.

Drivetrain System:

On-Demand, True AWD/2WD with VersaTrac™ for selectable engagement and enhanced traction.

Ergonomics Comfort:

Dual-seat configuration with passenger backrest and footrests, ergonomic rider controls, power steering (often standard or optional on touring models).

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service, Repair, Workshop

Secondary Coverage:

Troubleshooting, Diagnostics, Maintenance, Overhaul

Page Count

Page Count:

Unknown (PDF download format implies variable page count based on display/print settings, but a definitive number is not provided).

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English (assumed based on typical product descriptions for this market)

Format

Format:

PDF Download

Licensing

Licensing:

No Extra Fees, No Expiry Dates

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, inspection, overhaul, and reassembly. Includes cylinder head, pistons, connecting rods, crankshaft, valve train, timing components.

Engine Fuel System:

EFI system diagnosis, fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, lines.

Engine Ignition System:

Ignition coil, spark plugs, CDI unit, timing control, sensors.

Engine Cooling System:

Radiator, fan, coolant pump, thermostat, hoses, coolant specifications.

Transmission Drive System:

CVT (Continuously Variable Transmission) system, drive belts, clutches (primary and secondary), gearcase, fluid specifications, service procedures.

Drivetrain:

Front and rear drive shafts, differentials, axles, U-joints, wheel hubs, bearing service.

Suspension Steering:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment, steering system, tie rods, steering column, power steering (if equipped).

Braking System:

Hydraulic brake system, calipers, master cylinder, brake lines, brake pads, rotors, brake fluid specifications, bleeding procedures.

Electrical System:

Battery, charging system (stator, rectifier/regulator), starter motor, lighting system (headlights, taillights, indicators), wiring diagrams, fuses, relays, switches, instrumentation.

Body Chassis:

Frame, body panels, plastics, seating, racks, fenders, bumpers, storage compartments.

Diagnostics Troubleshooting:

Systematic troubleshooting procedures for common and uncommon issues, fault code interpretation (if applicable to EFI system), diagnostic charts.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug service, drive belt inspection/replacement, lubrication points, tire pressure checks, brake inspection.

Engine Repair:

Top-end rebuilds, bottom-end overhauls, piston ring replacement, valve adjustments, gasket replacement.

Transmission Repair:

CVT clutch service, drive belt replacement, gearcase maintenance, seal replacement.

Suspension Steering Repair:

Ball joint replacement, tie rod end replacement, shock absorber replacement, bushing replacement, steering linkage service.

Brake System Repair:

Brake pad replacement, rotor replacement, brake line replacement, brake caliper service, brake bleeding.

Electrical Troubleshooting:

Wiring harness repair, component testing (stator, regulator, starter), battery charging system diagnosis.

Bodywork Repair:

Panel removal and installation, fender repair, rack mounting and repair.

Special Tools:

Identification and usage of specialized tools required for specific repairs and adjustments.

Technical Depth

Depth Level:

Comprehensive Factory Level

Detail Level:

Detailed step-by-step instructions with diagrams and illustrations.

Diagnostic Capability:

Advanced diagnostic procedures for EFI and electrical systems, including component testing and troubleshooting trees.

Rebuild Procedures:

Full engine and transmission rebuild specifications, including clearances, torque values, and tolerances.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely searchable text within the PDF for keywords (common for factory manuals).

Print Quality

Print Quality:

High-resolution, suitable for professional printing. (Implied by 'Professional Manual')

Binding Type

Binding Type:

N/A (Digital download format)

Paper Type

Paper Type:

N/A (Digital download format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

800cc, 4-stroke, SOHC, V-twin

Displacement:

760 cc (46.4 cubic inches)

Bore X Stroke:

Approximately 90 mm x 59 mm (specifications may vary slightly by exact year/build).

Cooling System:

Liquid-cooled

Valvetrain:

SOHC (Single Overhead Camshaft), 4 valves per cylinder

Performance

Horsepower:

Typically around 55-60 HP (actual figures may vary slightly by model year).

Torque:

Not precisely specified in product data, but the 800cc V-twin is known for strong low-end and mid-range torque, crucial for towing and hauling.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane or higher

Fuel Tank Capacity:

Typically around 5.25 gallons (19.9 liters).

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

On-Demand, True AWD/2WD with VersaTrac™

Features

Clutches:

Primary and Secondary Clutch system for CVT operation.

Cvg Ratio:

Continuously Variable Gear Ratio, optimized for power and efficiency across the operating range.

📐 Dimensions

Exterior

Length:

Approximately 85.2 inches (216.4 cm) for 2009-2011 models.

Width:

Approximately 47.2 inches (119.9 cm) for 2009-2011 models.

Height:

Approximately 47 inches (119.4 cm) for 2009-2011 models.

Wheelbase:

Approximately 56.5 inches (143.5 cm) for 2009-2011 models.

Ground Clearance:

Typically around 11.5 inches (29.2 cm).

Cargo

Front Rack Capacity:

Typically around 100 lbs (45 kg).

Rear Rack Capacity:

Typically around 200 lbs (91 kg).

Weights

Dry Weight:

Approximately 694 lbs (315 kg) for 2009-2011 models.

Gross Vehicle Weight – consult manual for specific figures including rider and payload.

🛡️ Safety Features

Ratings

Atv Safety Standards:

Manufactured to meet ANSI standards for Class 1 ATVs. (General industry practice).

Rollover Protection:

Not equipped with a roll cage or seatbelts; requires proper ATV riding techniques and protective gear.

Active Features

Braking System:

Hydraulic disc brakes front and rear, with often a single-lever braking system for front and rear, and a thumb throttle.

Drivetrain Engagement:

On-Demand True AWD allows riders to switch between 2WD and AWD instantly.

Passive Features

Lighting:

Dual headlights, taillight/brake light, and often a handlebar-mounted pod light for enhanced visibility.

Ergonomic Controls:

Designed for rider comfort and control, with intuitive lever placement.

Engine Braking:

PVT transmission provides engine braking for controlled descents.

💡 Technology Features

Infotainment

Instrumentation:

Digital instrumentation typically includes speedometer, odometer, trip meter, tachometer, fuel gauge, gear indicator (if applicable), clock, and diagnostic indicators.

Driver Assistance

AWD System:

Polaris's On-Demand True AWD system automatically engages all four wheels when traction is lost, providing superior grip.

Engine Management:

EFI and engine control module (ECM) manage fuel delivery, ignition timing, and other parameters for optimal performance and emissions.

Connectivity

Diagnostic Ports:

Diagnostic port for connection to service tools to read fault codes and monitor engine parameters.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 100 hours or 6 months, whichever comes first. Consult manual for specific grade and capacity.

Air Filter Cleaning Replacement:

Inspect every 20 hours, clean as needed, replace annually or as per condition.

Spark Plug Service:

Inspect every 100 hours, replace as needed. Gap specification is critical.

Drive Belt Inspection Replacement:

Inspect every 100 hours, replace based on wear and condition. Belt life varies significantly with usage.

Gearcase Oil Change:

Typically every 200 hours or annually. Specific lubricant grade is crucial.

Fluid Specifications

Engine Oil Type:

Polaris recommends specific synthetic or semi-synthetic ATV engine oil, typically SAE 0W-40 or 5W-50, meeting API service classification SG or higher. Always verify with the manual.

Engine Oil Capacity:

Approximately 2.0 US quarts (1.9 liters) with filter change. Exact capacity in manual.

Gearcase Oil Type:

Polaris synthetic gearcase lubricant or equivalent, typically SAE 75W-90 GL-4. Consult manual for exact specification.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors, mixed 50/50 with distilled water.

Known Issues

Drive Belt Wear:

Drive belts on CVTs can wear prematurely if subjected to excessive heat, slipping, or improper engagement. Regular inspection and replacement are key.

Efi Sensor Issues:

Like many EFI systems, sensors (e.g., throttle position sensor, MAP sensor) can sometimes require cleaning or replacement if performance issues arise.

Suspension Bushings:

Bushings in A-arms and pivot points can wear over time, leading to play and potential noise. Regular lubrication and inspection are recommended.

Charging System Reliability:

While generally robust, early models of charging systems (stator, regulator/rectifier) could occasionally be a point of failure. The manual will detail testing procedures.

📚 Vehicle History

Brand Heritage

Polaris History:

Polaris Industries is a long-standing American manufacturer, established in 1954, known for its innovation in snowmobiles, ATVs, and off-road vehicles.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its versatility, comfort, and capability. The Touring models specifically cater to riders who prioritize longer-distance comfort and the ability to carry a passenger.

800Cc Engine Introduction:

The 800cc V-twin engine became a staple in Polaris's ATV lineup during the late 2000s, offering a significant power upgrade over smaller displacement engines.

Production

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States, with key facilities in Minnesota and other locations.

🏆 Awards & Recognition

Recognitions

Atv Reviews:

The Polaris Sportsman series generally received positive reviews for its power, handling, and comfort during its production run. Specific awards for the 2009-2011 800 Touring model would require dedicated historical research but it was considered a top-tier offering.