Engine:
Detailed disassembly, assembly, inspection, and repair of the 790cc liquid-cooled, 4-stroke, SOHC, V-twin engine.
Fuel Injection:
Comprehensive coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, throttle body, sensors (MAP, TPS, IAT, ECT), ECM diagnosis and calibration.
Body Steering Suspension:
Includes body panel removal/installation, steering system components (handlebars, steering shaft, tie rods), front and rear suspension (shocks, springs, control arms, bushings), wheel alignment.
Clutch System:
Detailed procedures for servicing the primary and secondary clutch systems, including belt inspection, replacement, clutch engagement/disengagement specifications, and weight/spring tuning.
Final Drive:
Coverage of the AWD (All-Wheel Drive) system, front and rear differential maintenance, driveshaft inspection, CV joints, and axle replacement.
Transmission:
Service and repair of the automatic transmission (PVT - Polaris Variable Transmission), including gear selection, lubrication, and component checks.
Brakes:
Front and rear brake system service, including hydraulic brake lines, master cylinders, calipers, brake pads, rotors, bleeding procedures, and parking brake adjustment.
Electrical:
Extensive electrical system troubleshooting, including battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and accessory circuits.
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems, essential for fault diagnosis.
International Model:
Specific details and potential variations for the '800 Touring EFI International' model are covered.
General Information:
Vehicle identification, safety precautions, torque specifications, general maintenance procedures.
Maintenance:
Regular scheduled maintenance tasks, including oil changes, filter replacements, lubrication points, spark plug checks, and fluid level checks.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common issues across all major vehicle systems.
Repair Rebuild:
Detailed step-by-step instructions for the complete disassembly, repair, and reassembly of major components and systems.
Technical Data:
Comprehensive technical data, including specifications, measurements, tolerances, and test procedures.
Depth:
Expert level. Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
Diagrams Pictures:
Includes diagrams and pictures to illustrate procedures and component identification.
Parts List:
A complete list of parts for the 2009 Polaris Sportsman 800 EFI models.
Engine Type:
Liquid-Cooled, 4-Stroke, SOHC, V-Twin
Displacement:
790 cc (48.2 cu. in.)
Bore X Stroke:
93.5 mm x 73 mm (3.68 in. x 2.87 in.)
Horsepower:
Approximately 50-55 HP (typical for this engine in 2009, exact figures may vary by source and specific tune)
Torque:
Refer to manual for specific torque figures; expected to be in the range of 45-50 lb-ft.
Fuel Delivery:
Electronic Fuel Injection (EFI) with automatic choke.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Oil Type:
Polaris PS-4 Synthetic 5W-50 or equivalent.
Oil Capacity:
Refer to manual for exact capacity with filter change (typically around 2.5 quarts).
Type:
Liquid-cooled with fan.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Polaris Premium Antifreeze) mixed 50/50 with distilled water.
Engine Oil Change:
Every 100 hours or 6 months (refer to manual for precise interval and usage conditions).
Clutch Belt Inspection:
Inspect at 50 hours, replace as needed based on wear.
Spark Plug Check:
Check and gap every 50 hours.
Air Filter Cleaning:
Clean every 25 hours or more frequently in dusty conditions.
Engine Oil:
Polaris PS-4 Synthetic 5W-50.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Gearcase Oil Front:
Refer to manual for specific Polaris Demand Drive fluid.
Gearcase Oil Rear:
Refer to manual for specific Polaris Synthetic Gearcase Oil.
Clutch Wear:
Variable Transmission (PVT) belt wear and clutch component wear are common maintenance items, requiring regular inspection and replacement.
Efi Sensor Issues:
EFI system sensors (like TPS, MAP) can sometimes be a source of running issues, requiring diagnostic checks.
Suspension Bushings:
Wear in suspension bushings can lead to play and degradation of handling over time.
Polaris History:
Polaris Industries, founded in 1954, is a leading American manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, known for its off-road capability, independent rear suspension (IRS), and AWD systems, evolving significantly since its introduction.
Manufacturing Location:
Primarily manufactured in Roseau, Minnesota, USA, and other Polaris facilities.
