Welcome to the owner's manual for the 2008 Sportsman 800 Touring EFI, a premium All-Terrain Vehicle (ATV) engineered for comfort, capability, and extended riding adventures. This model, a cornerstone of the renowned ATV lineup, features a powerful 760cc V-twin engine, independent rear suspension for a superior ride, electric power steering, and comfortable two-up seating, making it ideal for exploring challenging terrain or enjoying leisurely excursions. With its deep heritage in powersports, the Sportsman series has been built on a foundation of reliability and off-road prowess, and the 800 Touring EFI exemplifies this commitment to performance and rider experience.
This comprehensive service and repair manual provides detailed information essential for maintaining and repairing your 2008 Sportsman 800 Touring EFI. It covers all critical systems, including the engine, fuel system, drivetrain, transmission, suspension, steering, brakes, and electrical system, offering step-by-step procedures for routine maintenance, troubleshooting, component diagnosis, and complete overhauls. With in-depth coverage of diagnostic procedures, assembly and disassembly, electrical schematics, and precise torque specifications, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to ensure optimal performance and longevity of their ATV.
Model:
Sportsman 800 Touring EFI
Vehicle Type:
ATV (All-Terrain Vehicle)
Vin Code:
Typically 17 characters, starting with a "4" for Polaris
Market Position:
The Polaris Sportsman 800 Touring EFI was positioned as a premium, high-performance two-up ATV, designed for comfort, capability, and extended riding adventures.
Competitive Analysis:
Competed against other large-displacement, utility/recreational ATVs from manufacturers like Can-Am (Outlander series), Arctic Cat (Prowler series), and Yamaha (Grizzly series).
Key Features:
Powerful 800cc V-twin engine, independent rear suspension (IRS) for superior ride quality, electric power steering (EPS), comfortable two-up seating, On-Demand AWD, robust chassis.
Coverage Areas:
Complete service and repair for 2008 Polaris Sportsman 800 Touring EFI
Page Count:
Estimated 500+ pages (typical for a comprehensive service manual)
Manual Type:
Service Repair Manual
Format:
PDF (Digital Download)
Systems Covered:
Engine, Fuel System, Drivetrain, Transmission, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork, Cooling System, Exhaust System, Emissions Control
Procedures Included:
Routine Maintenance, Troubleshooting, Component Diagnosis, Repair Procedures, Overhaul Instructions, Electrical System Schematics, Torque Specifications, Special Tool Requirements
Diagnostic Procedures:
Detailed diagnostic flowcharts and troubleshooting guides for common issues, electrical system faults, and engine performance problems.
Assembly Disassembly:
Step-by-step instructions for the disassembly and reassembly of all major components, including engine, transmission, suspension, steering, and body panels.
Technical Depth:
Comprehensive, covering all aspects from basic fluid changes to complete engine and transmission rebuilds, electrical diagnostics, and suspension adjustments.
Electrical Schematics:
Complete wiring diagrams, component location charts, and diagnostic procedures for the entire electrical system, including ignition, lighting, charging, and accessories.
Torque Specifications:
Comprehensive list of all critical torque specifications for fasteners throughout the vehicle.
Print Quality:
High-resolution, enabling clear reproduction of diagrams, schematics, and text.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Type:
4-stroke, Twin Cylinder, SOHC, Liquid-Cooled
Bore X Stroke:
92.0 mm x 72.0 mm
Horsepower Est:
Approx. 55 HP (at crankshaft)
Torque Est:
Approx. 48 ft-lbs (at crankshaft)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Oil Type:
SAE 10W-50 Synthetic (Polaris recommends)
Oil Capacity:
3.0 US quarts (2.8 Liters) with filter change
Coolant Type:
Ethylene Glycol Based Antifreeze (50/50 mix with distilled water)
Coolant Capacity:
Approx. 2.0 US quarts (1.9 Liters)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Gear Selection:
Park, Reverse, Neutral, Low, High
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/AWD selector
Transmission Fluid Type:
Polaris Synthetic Gearcase Lubricant (or equivalent SAE 75W-140)
Transmission Fluid Capacity:
Approx. 0.25 US quarts (0.24 Liters)
Length:
85.1 inches (216.2 cm)
Width:
47.2 inches (119.9 cm)
Height:
53.5 inches (135.9 cm)
Wheelbase:
56.6 inches (143.8 cm)
Ground Clearance:
11.5 inches (29.2 cm)
Dry Weight:
747 lbs (339 kg)
Towing Capacity:
1,500 lbs (680.4 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
Cargo Box Type:
Integrated rear cargo rack
Cargo Box Volume:
N/A (rack-based)
Safety Ratings:
Not applicable to ATVs in the same way as passenger vehicles; adherence to industry safety standards (e.g., ANSI, BRP) is expected.
Active Features:
Engine Braking System (EBS) on downhill descents, On-Demand AWD for traction management, powerful hydraulic disc brakes.
Passive Features:
Rollover Protection Structure (ROPS) not standard but recommended for modifications, seatbelts (if used for specific applications), handguards.
Infotainment System:
Basic instrumentation cluster with speedometer, odometer, trip meter, fuel gauge, and indicator lights. No advanced infotainment system typically found on automotive vehicles.
Driver Assistance Features:
Electric Power Steering (EPS) is a key driver assistance feature, reducing steering effort and fatigue.
Connectivity Options:
None (standard for this era of ATV)
Headlight Type:
Dual Halogen headlights
Taillight Type:
LED tail/brake light
Oil Change Interval:
Every 100 hours or annually, whichever comes first.
Spark Plug Interval:
Inspect every 100 hours, replace as needed.
Air Filter Interval:
Inspect every 50 hours or after dusty riding, clean/replace as needed.
Transmission Fluid Interval:
Change every 200 hours or annually.
Coolant Change Interval:
Flush and replace every 2 years or 200 hours.
Brake Fluid Type:
DOT 3 or DOT 4
Chassis Grease Type:
Lithium-base EP (Extreme Pressure) grease
Common Issues:
Potential for belt slippage in the PVT system under heavy load, occasional electrical connector issues, suspension wear over time, fuel pump longevity concerns.
Recall Information:
Refer to official Polaris service bulletins and NHTSA for any applicable recalls for this model year.
Brand Heritage:
Polaris Industries, founded in 1954, has a long history of producing snowmobiles, ATVs, and other powersports vehicles, known for innovation and off-road capability.
Model Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, with the 800cc engine representing a significant step up in performance and capability, evolving to include touring-focused variants for comfort and two-up riding.
Production Years:
The 800cc engine was offered in various Sportsman models between roughly 2005 and 2014 before being superseded by newer engine platforms.
Manufacturing Location:
Primarily manufactured at Polaris's facilities in the United States.
Recognitions:
The Polaris Sportsman line has consistently received positive reviews and accolades from off-road publications for its performance, comfort, and utility.
Ratings:
Highly rated for its smooth ride, powerful engine, and handling, especially in touring configurations.
Certifications:
Manufactured to meet relevant industry safety and emissions standards.
