🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 800 EFI X2 / Sportsman 800 EFI Touring

Model Variant:

X2, Touring

Year:

2009

Product Type:

Factory Service Repair Manual

Platform Code:

Not specified in product information

Engine Code:

Not specified in product information, likely refers to the 800cc EFI engine

👋 Introduction

Positioning:

The 2009 Polaris Sportsman 800 EFI X2 and Touring models represent Polaris's robust offerings in the utility and touring ATV segment, known for their powerful engines and versatile capabilities. This manual targets owners and technicians requiring in-depth knowledge for maintenance and repair.

Competitors:

Competes with models from Yamaha (Grizzly), Can-Am (Outlander), Honda (Rancher/Foreman), and Suzuki (KingQuad) in the 800cc class, emphasizing performance and features.

Versatility:

The X2 variant offers a unique rear passenger seat that converts to a cargo bed, enhancing utility. The Touring model prioritizes rider comfort and extended range for longer journeys.

Authoritative Source:

As a factory service manual, it is the definitive guide, reflecting the official procedures and specifications used by Polaris-certified technicians.

Accessibility:

Instant PDF download provides immediate access to critical repair information, bypassing shipping delays and costs.

📋 Manual Details

General Information:

Yes

Maintenance:

Yes

Engine:

Yes

Fuel Injection:

Yes

Body:

Yes

Steering:

Yes

Suspension:

Yes

Clutch System:

Yes

Final Drive:

Yes

Transmission:

Yes

Brakes:

Yes

Electrical:

Yes

Wiring Diagrams:

Yes

Touring Efi International:

Yes

Estimated Page Count:

Not specified, but a comprehensive factory service manual typically ranges from 500-1000+ pages.

Type:

Factory Service Repair Manual

Language:

English (assumed based on product description)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, connecting rods, crankshaft, cylinder head, valves, camshafts, timing components).

Fuel System:

Detailed coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, fuel pressure regulator, throttle body, sensors (TPS, MAP, IAT, ECT), ECU diagnosis, and fuel tank servicing.

Drivetrain:

Comprehensive coverage of the automatic transmission (PVT - Polaris Variable Transmission), including belt inspection/replacement, clutch servicing (primary and secondary), gearbox, differential, and driveshaft maintenance and repair.

Electrical System:

Extensive coverage of the electrical system, including battery, charging system (stator, rectifier/regulator), starter motor, ignition system, lighting, instrumentation, accessory circuits, and troubleshooting using wiring diagrams.

Chassis And Body:

Covers frame inspection, body panel removal/installation, fenders, racks, seat assembly, handlebars, and general cosmetic repairs.

Suspension And Steering:

Detailed procedures for front and rear suspension components, including shocks, springs, control arms, ball joints, bushings, wheel bearings, and the steering system (tie rods, steering shaft, steering rack).

Braking System:

Coverage includes hydraulic brake system components, brake lines, master cylinders, calipers, brake pads, rotors, and bleeding procedures.

Preventive Maintenance:

Detailed scheduled maintenance procedures, including fluid changes (engine oil, transmission fluid, brake fluid, coolant), filter replacements (oil, air), spark plug checks, belt inspection, and lubrication points.

Troubleshooting Guides:

Systematic diagnostic procedures and flowcharts to identify and resolve common mechanical and electrical issues.

Repair Procedures:

Step-by-step instructions for component removal, repair, replacement, and reinstallation for all major systems.

Disassembly And Assembly:

Complete breakdown and reassembly procedures for engine, transmission, suspension, and other key components.

Wiring Diagram Interpretation:

Detailed, manufacturer-specific wiring diagrams to aid in electrical system diagnostics and repair.

Torque Specifications:

Essential torque values for all critical fasteners and components to ensure proper assembly and prevent damage.

Depth:

Comprehensive factory-level detail, suitable for both professional mechanics and experienced DIY enthusiasts. Covers routine maintenance, in-depth diagnostics, component overhaul, and complete system rebuilds.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Quality:

Assumed high-quality scan or original digital file, suitable for printing essential sections.

Binding:

N/A (Digital PDF Download)

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, Twin-Cylinder, 4-Valve per cylinder

Displacement:

775cc (47.3 cu. in.)

Cooling System:

Liquid-cooled

Bore X Stroke:

Not specified in product information, but typical for this class.

Compression Ratio:

Not specified in product information.

Horsepower:

Approximately 55-60 HP (estimate based on typical 800cc ATVs of this era).

Torque:

Not specified in product information.

Fuel Delivery:

Electronic Fuel Injection (EFI) with throttle body

Fuel Type:

Unleaded gasoline (Octane rating typically 87 or higher, check manual for specifics)

Ignition System:

Electronic ignition

🔧 Transmission

Transmission Type:

Automatic Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive, On-Demand All-Wheel Drive (AWD) / 2WD

Optional Features:

Not applicable for this model as described.

Clutch System:

Dual centrifugal clutches (primary and secondary) for automatic ratio adjustment.

📐 Dimensions

Length:

X2: 85 in. (215.9 cm) / Touring: 93.5 in. (237.5 cm) (Approximate, based on typical specifications for these models)

Width:

48 in. (121.9 cm) (Approximate)

Height:

48 in. (121.9 cm) (Approximate)

Dry Weight:

X2: ~700 lbs (317.5 kg) / Touring: ~750 lbs (340.2 kg) (Approximate, based on typical specifications)

Ground Clearance:

11.5 in. (29.2 cm) (Approximate)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg) (X2 may differ when configured for passenger)

🛡️ Safety Features

Safety Certifications:

Not typically rated by NHTSA or IIHS as these are off-road vehicles.

Braking:

Hydraulic disc brakes (front and rear), engine braking via PVT.

Suspension:

Independent front and rear suspension for stability and control over uneven terrain.

Drive System:

On-Demand AWD provides enhanced traction.

Lighting:

Dual headlights, brake light.

Ergonomics:

Handlebar design and seating position optimized for control and comfort.

💡 Technology Features

Instrument Cluster:

Digital instrumentation with speedometer, odometer, trip meter, engine hour meter, tachometer, fuel gauge, AWD indicator, and diagnostic fault codes.

Engine Braking:

Integrated engine braking through the PVT system enhances control during descents.

Accessory Power:

Typically includes a DC power outlet for charging accessories.

Diagnostic Port:

Likely equipped with a diagnostic port for connection to Polaris diagnostic software for advanced troubleshooting.

🔧 Maintenance

Engine Oil Change:

Typically every 100 hours or 6 months (refer to manual for precise interval and operating conditions).

Air Filter Cleaning:

Inspect every 25 hours, clean/replace as needed, especially in dusty conditions.

Transmission Fluid Change:

Refer to manual, typically checked with engine oil change or annually.

Spark Plug Replacement:

Refer to manual, often around 200-400 hours or annually.

Engine Oil Type:

Polarisкомендует 0W-40 Synthetic (check manual for exact specification and viscosity grade for ambient temperatures).

Engine Oil Capacity:

Refer to manual, typically around 2.5 quarts (2.4 liters) with filter change.

Transmission Fluid Type:

Polaris Agricultural Gearcase Lube or equivalent GL-5 75W-90 (check manual for specific gearbox fluid).

Coolant Type:

Ethylene glycol based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for exact specification).

Common Wear Items:

Drive belts (PVT), wheel bearings, ball joints, tie rod ends, and bushings are common wear items on ATVs of this age and usage.

Efi System:

While generally reliable, EFI systems can be susceptible to sensor failures or clogged injectors, often addressable with proper maintenance and diagnostic tools.

📚 Vehicle History

Polaris History:

Polaris Industries is a long-standing American manufacturer of powersports vehicles, established in 1954, with a strong reputation for innovation and off-road vehicle development.

Sportsman Lineage:

The Sportsman line has been a flagship for Polaris, continuously evolving to incorporate more powerful engines, advanced suspension, and feature sets like the X2's convertible seating and the Touring model's ergonomic enhancements.

Manufacturing Location:

Polaris ATVs are typically manufactured in the USA, primarily at their facilities in Minnesota and Iowa.

🏆 Awards & Recognition

Industry Awards:

Polaris Sportsman models frequently receive accolades from ATV magazines and industry publications for performance, utility, and innovation in their respective model years.

Consumer Reviews:

Generally well-regarded by owners for power and off-road capability, though specific issues can vary by usage and maintenance.

Emissions:

Meets relevant emissions standards for its model year and market of sale.