Polaris Sportsman 800 Touring 2008 Service Repair Manual

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Stichworte: 2008 ATV Misc Polaris Powersports Sportsman 800 Touring

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Beschreibung

The Polaris Sportsman 800 Touring, model year 2008, is a high-performance, two-up All-Terrain Vehicle (ATV) designed for recreational riders and utility users who require passenger capacity and off-road capability. Engineered with a powerful 760cc V-twin engine and independent front and rear suspension, it offers superior ride comfort and handling. Its robust construction, significant towing capacity, and on-demand all-wheel-drive system make it a versatile choice for various terrains and tasks. The tandem seating configuration and ergonomic controls further enhance the experience for both rider and passenger, positioning it as a capable competitor in its segment. This Service Repair Manual provides comprehensive technical information for the Polaris Sportsman 800 Touring. It covers detailed step-by-step repair procedures, complete diagnostic procedures for all major systems, and in-depth troubleshooting guides for common and uncommon issues. The manual includes comprehensive scheduled maintenance intervals, extensive electrical system wiring diagrams, and precise torque specifications. With factory-level detail suitable for professional technicians and advanced DIY enthusiasts, this manual is an essential resource for maintaining, troubleshooting, and repairing the vehicle, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 800 Touring

Year:

Codes

Chassis Code:

A08SN80AA

Engine Code:

R2B800P

👋 Introduction

Market Position

Vehicle Segment:

High-performance, 2-up ATV (All-Terrain Vehicle).

Target Audience:

Recreational riders, utility users requiring passenger capacity, off-road enthusiasts.

Competitive Analysis

Competitors:

Can-Am Outlander Max, Arctic Cat Thundercat, Yamaha Grizzly, Honda Foreman Rubicon.

Key Features

Seating:

Tandem seating for rider and passenger.

Engine Size:

Powerful 800cc V-twin engine.

Suspension Type:

Independent front and rear suspension for superior ride comfort and capability.

Towing Capacity:

Significant towing capability for utility tasks.

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Complete diagnostic procedures for all major systems.

Repair Procedures:

Detailed step-by-step repair procedures for all components and systems.

Maintenance Schedules:

Comprehensive scheduled maintenance intervals and procedures.

Wiring Diagrams:

Extensive electrical system wiring diagrams.

Troubleshooting Guides:

In-depth troubleshooting guides for common and uncommon issues.

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, and diagnostics.

Fuel System:

Fuel injection system, fuel pump, injectors, fuel filter replacement.

Ignition System:

Ignition coils, spark plugs, timing, ignition control module.

Cooling System:

Radiator, thermostat, water pump, coolant flow, flush and fill procedures.

Transmission Drivetrain:

PVT (Polaris Variable Transmission) system, belt replacement, clutch service, driveshafts, differentials.

Suspension:

Front and rear suspension components, shocks, springs, bushings, alignment.

Brakes:

Hydraulic brake system, caliper service, pad replacement, fluid flush, brake lines.

Electrical System:

Battery, charging system, starter, lighting, switches, sensors, ECU.

Steering System:

Handlebar, steering column, tie rods, steering rack service.

Body Chassis:

Frame inspection, body panel removal/installation, seat service, rack systems.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire pressure adjustments.

Engine Rebuild:

Complete engine disassembly, inspection, component replacement, and reassembly.

Transmission Service:

PVT belt inspection/replacement, clutch alignment, gear case oil service.

Brake System Repair:

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

Electrical Troubleshooting:

Diagnosis of starting, charging, lighting, and sensor issues using wiring diagrams.

Suspension Overhaul:

Replacement of shocks, control arms, bushings, and ball joints.

Steering Component Replacement:

Tie rod ends, steering shafts, and linkage servicing.

Cooling System Maintenance:

Radiator flush, coolant replacement, thermostat replacement.

Torque Specifications:

Precise torque values for all fasteners.

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and advanced DIYers.

Diagnostic Tools:

Information on specialized tools and diagnostic equipment.

Component Testing:

Detailed procedures for testing individual components and electrical circuits.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Diagram Quality:

High-quality, clear, and detailed diagrams and illustrations.

Text Legibility:

Easy-to-read text sections.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, 8-valve, SOHC, V-twin

Displacement:

760cc

Bore X Stroke:

90 mm x 59 mm

Cooling System:

Liquid-cooled

Horsepower Estimated:

Approximately 53 hp @ 6000 RPM

Torque Estimated:

Approximately 55 lb-ft @ 4750 RPM

Performance

Redline Rpm:

6500 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with 44mm throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane minimum

Fuel Tank Capacity:

4.1 gallons (15.5 L)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

On-Demand All-Wheel Drive (AWD)

Final Drive:

Shaft Drive

Features

Clutch Engagement:

Roller primary clutch for smooth engagement.

Engine Braking:

Standard engine braking for downhill control.

📐 Dimensions

Exterior

Length:

83 in (210.8 cm)

Width:

48 in (121.9 cm)

Height:

49.5 in (125.7 cm)

Wheelbase:

56.5 in (143.5 cm)

Ground Clearance:

10.5 in (26.7 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Weights

Dry Weight:

664 lbs (301 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

Hitch Type:

2" receiver

🛡️ Safety Features

Ratings

Rollover Protection:

N/A (ATV, rider assumes risk)

Active Features

Braking System:

Hydraulic disc brakes on all wheels.

Engine Braking:

Provided by PVT system for controlled descents.

AWD System:

On-Demand AWD for enhanced traction.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Ergonomics:

Comfortable seating for two, ergonomic controls.

Handguards:

Standard handguards for rider protection.

💡 Technology Features

Infotainment

Display Unit:

Digital instrument cluster displaying speed, RPM, fuel level, gear selection, and odometer.

Driver Assistance

ADC (Active Descent Control) can be integrated to aid in controlled descents, though less common on base models.

Connectivity

Charging Port:

Often includes a 12V accessory outlet for charging devices.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually.

Spark Plug Replacement:

Every 100 hours or annually.

Air Filter Cleaning:

Every 25 hours, or more frequently in dusty conditions.

Pvt Belt Inspection:

Every 50 hours or annually.

Fluid Specifications

Engine Oil Type:

SAE 0W-40 Synthetic (Polaris recommends their brand, but API SG or higher is acceptable).

Engine Oil Capacity:

Approximately 2.7 US quarts (2.5 L) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze, compatible with aluminum engine blocks (e.g., Polaris Engage).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Gear Case Oil Type:

SAE 80W-90 Hypoid Gear Lubricant (Polaris recommends their brand).

Gear Case Oil Capacity:

Approximately 8 US fluid ounces (0.24 L).

Known Issues

Pvt Belt Wear:

Early wear or breakage of the PVT belt can occur if ridden excessively with the engine under heavy load or if clutch alignment is off.

Suspension Bushings:

Front and rear suspension bushings can wear over time, leading to play and potential alignment issues.

Starter Solenoid:

Some models may experience issues with the starter solenoid failing to engage.

Efi Sensor Issues:

Less common, but throttle position sensors or other EFI sensors can sometimes cause performance issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Polaris has a long history in powersports, particularly with ATVs, known for innovation and performance.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship ATV series, offering a range of models for various purposes, with the Touring models emphasizing comfort and passenger capability.

Production

Production Location:

Assembly typically occurs at Polaris manufacturing facilities in the USA.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Polaris Sportsman models have historically received numerous positive reviews and awards for performance, comfort, and utility from powersports publications.

Ratings

Consumer Ratings:

Generally well-regarded for its powerful engine and comfortable ride.