Polaris Sportsman Touring 800 EFI ATV Complete Workshop Service Repair Manual 2009 2010 2011

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Art.-Nr: 94569

Stichworte: 2009 2010 2011 ATV Misc Polaris Powersports Sportsman Touring 800 EFI

Produktvarianten

Beschreibung

The Polaris Sportsman Touring 800 EFI is a premium utility All-Terrain Vehicle (ATV) designed for a wide range of applications, from recreational riding and hunting to demanding farm work. Produced for the 2009, 2010, and 2011 model years, this ATV is powered by a robust 800cc V-twin ProStar engine featuring Electronic Fuel Injection (EFI) for optimal performance and efficiency across diverse conditions. Its engineering emphasizes touring comfort, with ergonomic design, comfortable seating for two, and practical storage solutions. The independent front and rear suspension, combined with an On-Demand All-Wheel Drive (AWD) system, ensures superior ride quality, handling, and traction on challenging terrain. With a substantial towing capacity of 1,500 lbs and generous rack capacities, the Sportsman Touring 800 EFI is a versatile and capable machine. This comprehensive workshop service and repair manual is your essential guide for maintaining and repairing your Polaris Sportsman Touring 800 EFI. Covering over 500 pages of detailed information in English, it provides in-depth instructions for every aspect of the vehicle. Key areas include complete engine overhaul and tuning for the ProStar 800 EFI, fuel system diagnostics, ignition system maintenance, cooling system service, transmission (PVT) operation and repair, drivetrain components, suspension and steering adjustments, braking system servicing, and the entire electrical system. The manual also offers detailed troubleshooting charts, routine maintenance procedures, rebuild instructions, and critical technical specifications, including torque values and fluid requirements. This resource is invaluable for owners, mechanics, and technicians to ensure the longevity and optimal performance of their ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 800 EFI

Product Type:

Complete Workshop Service Repair Manual

Codes

Engine Code:

ProStar 800 EFI

👋 Introduction

Market Position

Category:

Premium Utility ATV

Target Audience:

Recreational riders, hunters, farmers, and general utility users seeking a powerful and comfortable ATV.

Competitive Analysis

Key Competitors:

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

Key Features

Engine Power:

800cc V-twin engine delivering robust power and torque.

Touring Comfort:

Ergonomic design, comfortable seating for rider and passenger, storage solutions.

A Arm Suspension:

Independent front and rear suspension for superior ride quality and handling.

Efi System:

Electronic Fuel Injection for optimal performance and fuel efficiency in various conditions.

AWD System:

On-Demand AWD for excellent traction when needed.

📋 Manual Details

Coverage Areas

Model Years Covered:

2009, 2010, 2011

Vehicle Type:

ATV (All-Terrain Vehicle)

Region Applicability:

Global (standard specifications)

Page Count

Estimated Pages:

Manual Type

Manual Type:

Workshop Service & Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine System:

Complete overhaul, tuning, diagnostics, and repair of the ProStar 800 EFI engine.

Fuel System:

EFI system troubleshooting, fuel pump, injectors, throttle body, fuel filter replacement.

Ignition System:

CDI, spark plugs, ignition coils, timing adjustments.

Cooling System:

Radiator, fan, thermostat, coolant flush and replacement.

Exhaust System:

Muffler, exhaust pipe, catalytic converter inspection and replacement.

Transmission System:

PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch service, gearcase maintenance.

Drivetrain:

AWD system, front differential, rear differential, driveshafts, CV joints, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, A-arms, bushings, ball joints, alignment.

Steering:

Handlebar, tie rods, steering post, steering rack/mechanism, EPS (Electronic Power Steering) if applicable.

Braking System:

Front and rear hydraulic brakes, brake pads, rotors, calipers, brake lines, master cylinders, bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, accessories, wiring diagrams.

Frame And Body:

Chassis inspection, plastic body panels, seat, rack systems, fenders.

Troubleshooting:

Diagnostic charts for common problems, fault codes, performance issues.

Procedures Included

Maintenance:

Oil changes, filter replacements, lubrication points, brake adjustments, tire pressure checks.

Repair:

Component disassembly, reassembly, part replacement for all covered systems.

Diagnostics:

Step-by-step troubleshooting guides for electrical and mechanical issues.

Rebuilds:

Complete engine and transmission rebuild procedures.

Specifications:

Torque specifications for all fasteners, fluid capacities, electrical specifications.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.

Detail Level:

Detailed exploded views, diagrams, and step-by-step instructions.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Fully text-searchable for quick information retrieval.

Print Quality

Printability:

Printable, allowing users to create hard copies of specific sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, SOHC, V-twin

Displacement:

760cc (approx.)

Bore X Stroke:

76 mm x 74.5 mm (typical for this engine family)

Compression Ratio:

9.5:1 (typical)

Performance

Horsepower:

Approx. 50-55 HP (estimated)

Torque:

Approx. 48-52 lb-ft (estimated)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane

Lubrication

Oil Type:

SAE 5W-50 Synthetic (Refer to manual for specific Polaris recommendations)

Oil Capacity:

Approx. 2.0 Quarts (with filter change) (Refer to manual for exact capacity)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) with Engine Braking (EB)

Drive Modes:

High, Low, Neutral, Reverse, Park

Features

Belt Drive:

Automated continuously variable clutch system.

Gearcase Oil:

Polaris AGL Synthetic Gearcase Lubricant or equivalent (Refer to manual for specification and capacity)

Final Drive:

Shaft Drive (AWD)

📐 Dimensions

Exterior

Length:

Approx. 83 in. (210.8 cm)

Width:

Approx. 46 in. (116.8 cm)

Height:

Approx. 48 in. (121.9 cm)

Wheelbase:

Approx. 56 in. (142.2 cm)

Weights

Dry Weight:

Approx. 650 lbs (295 kg)

Ground Clearance:

Approx. 11.5 in. (29.2 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Towing

Towing Capacity:

1,500 lbs (680 kg)

Wheels And Tires

Front Tires:

26 x 8-14

Rear Tires:

26 x 10-14

Wheel Type:

Stamped steel or aluminum (depending on trim)

🛡️ Safety Features

Ratings

Rollover Protection:

ATVs are not subject to formal NCAP-style crash ratings; operator safety depends on responsible riding and protective gear.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

A Arm Design:

Independent suspension contributes to stability and control.

AWD Engagement:

On-Demand AWD for enhanced traction in slippery conditions.

Passive Features

Ergonomics:

Designed for rider comfort and control, reducing fatigue.

Lighting:

Dual halogen headlights and a single rear tail/brake light for visibility.

Operator Training:

Manual strongly emphasizes safe operating practices and the use of PPE (Personal Protective Equipment).

💡 Technology Features

Infotainment

Instrument Cluster:

Digital/analog gauge cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, AWD status.

Driver Assistance

Powertrain Management:

EFI system automatically adjusts fuel delivery for optimal performance and emissions.

Engine Braking:

Integrated engine braking (EB) via the PVT system assists in slowing down, especially on descents.

Connectivity

Accessory Power:

Pre-wired for accessories, often includes a 12V power outlet.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first.

Spark Plug Replacement:

Inspect every 100 hours, replace as needed.

Air Filter Cleaning:

Inspect every 50 hours, clean or replace as needed, more frequently in dusty conditions.

Transmission Belt Inspection:

Inspect every 100 hours for wear and damage.

Gearcase Oil Change:

Every 12 months or 200 hours.

Fluid Specifications

Engine Oil:

SAE 5W-50 Synthetic Motorcycle/ATV Oil

Coolant:

Ethylene Glycol based antifreeze, 50/50 mix with distilled water (e.g., Polaris Coolant)

Brake Fluid:

DOT 4 Hydraulic Brake Fluid

Grease:

Lithium-based multipurpose grease

Known Issues

Pvp Belt Wear:

Early wear or breakage of the primary drive belt can occur with aggressive riding or improper maintenance.

Charging System Issues:

Stator or regulator/rectifier failures can lead to battery charging problems.

Sus Suspension Component Wear:

Bushings and ball joints in the suspension can wear over time, requiring replacement for proper alignment and handling.

Efi Sensor Failures:

Sensors like the throttle position sensor (TPS) or coolant temperature sensor can fail, impacting engine performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc., established in 1954, a leading manufacturer of powersports vehicles.

Model Evolution

Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its utility and comfort.

800Cc Introduction:

The 800cc engine platform was a significant upgrade, providing a substantial power increase over previous 700cc models.

Touring Variant:

The 'Touring' designation signifies a focus on rider and passenger comfort, often including enhanced seating and ergonomics.

Production

Production Period:

The 800 EFI engine was a core offering for Polaris ATVs from the mid-2000s through the early 2010s.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2009-2011 Sportsman Touring 800 EFI might not be individually cataloged, the Polaris Sportsman line consistently receives praise for its utility, comfort, and performance in industry reviews and rider feedback.

Ratings

Rider Reviews:

Generally positive for its power, comfortable ride, and capability in varied terrain.