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Polaris Sportsman Touring 800 EFI 2009 Service Manual

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The 2009 Sportsman Touring 800 EFI is a premium all-terrain vehicle engineered for riders seeking a powerful, capable, and comfortable machine for touring, work, and recreation. This ATV boasts a...
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Tipo: Atv
Proveedor:
SKU: 58748
Polaris Sportsman Touring 800 EFI 2009 Service ManualPolaris Sportsman Touring 800 EFI 2009 Service ManualPolaris Sportsman Touring 800 EFI 2009 Service ManualPolaris Sportsman Touring 800 EFI 2009 Service Manual
The 2009 Sportsman Touring 800 EFI is a premium all-terrain vehicle engineered for riders seeking a powerful, capable, and comfortable machine for touring, work, and recreation. This ATV boasts a robust 779 cc V-twin engine with Electronic Fuel Injection (EFI) for responsive performance and efficient operation. Its extended wheelbase and independent rear suspension (IRS) provide enhanced passenger comfort and superior handling over varied terrain, while the On-Demand All-Wheel Drive (AWD) system automatically engages front traction when needed. With a significant towing capacity of 1500 lbs and ample rack storage, the Sportsman Touring 800 EFI is designed to tackle demanding tasks and adventurous journeys. This comprehensive service manual provides essential information for the maintenance, repair, and troubleshooting of your 2009 Sportsman Touring 800 EFI. It covers all major systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical systems, with detailed procedures for disassembly, assembly, and diagnostics. The manual includes critical technical specifications, torque values, wiring diagrams, and guidance on specialized tools. By following the step-by-step instructions and maintenance schedules outlined within, owners and technicians can ensure the optimal performance, reliability, and longevity of this versatile ATV.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman Touring 800 EFI
Year:
2009
Vehicle Type:
All-Terrain Vehicle (ATV)
Codes
Vin Code Digit 4:
8
Vin Code Digit 10:
9
👋 Introduction
Market Position
Vehicle Segment:
Premium Utility/Recreational ATV
Target Audience:
Riders seeking a powerful, capable, and comfortable ATV for touring, work, and recreation
Competitive Analysis
Competitors 2009:
Can-Am Outlander, Arctic Cat Thundercat, Yamaha Grizzly, Kawasaki Brute Force
Key Features
Engine Size:
Large displacement V-twin for significant power output
Touring Capability:
Longer wheelbase for enhanced passenger comfort and stability
Efi System:
Electronic Fuel Injection for improved throttle response, fuel efficiency, and cold starts
Independent Suspension:
IRS for superior ride quality and handling over rough terrain
On Demand AWD:
Automatic engagement of front wheels when traction is lost
📋 Manual Details
Coverage Areas
Manual Title:
Polaris Sportsman Touring 800 EFI 2009 Service Manual PDF Download
Manual Subtitle:
Workshop Repair Service Manual PDF Download
Primary Coverage:
Service, maintenance, and troubleshooting
Page Count
Estimated Page Count:
400-600 pages (typical for comprehensive service manuals of this era and type)
Manual Type
Manual Type:
Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, diagnostics, tuning, cooling system, lubrication system
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel tank, pressure regulator
Ignition System:
Ignition coils, spark plugs, ECU ignition control, timing
Transmission:
PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch maintenance, gear case service
Drivetrain:
All-wheel drive (AWD) system, front differential, rear differential, driveshafts, U-joints, CV joints
Suspension:
Front and rear suspension systems, shocks, springs, A-arms, bushings, bearings, wheel alignment
Brakes:
Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, rotors, bleeding procedure
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, wiring diagrams, fuses, relays, diagnostic connectors
Steering:
Handlebar, steering shaft, tie rods, ball joints, steering system adjustments
Bodywork Chassis:
Frame inspection, body panel removal/installation, seat, racks, guards
Cooling System:
Radiator, fan, coolant, hoses, thermostat
Procedures Included
Maintenance Procedures:
Regular inspections, fluid changes, filter replacements, belt checks, lubrication points
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, error codes
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul
Diagnostic Procedures:
EFI system diagnostics, electrical system testing, component testing
Assembly Disassembly:
Complete breakdown and reassembly procedures for major components
Wiring Diagrams:
Detailed electrical schematics for all systems
Technical Depth
Depth Of Coverage:
Comprehensive, covering basic to advanced repair and diagnostics
Diagnostic Tools:
Information on required diagnostic tools (e.g., diagnostic code reader, multimeter)
Torque Specifications:
Detailed torque values for critical fasteners
Special Tools:
Identification and usage of specialized tools required for certain procedures
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Likely text-searchable PDF, allowing for quick keyword lookup
Print Quality
Printability:
Designed for digital viewing and printing of individual pages or sections
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, 4-stroke, SOHC, 8-valve
Displacement:
779 cc (47.5 cu. in.)
Bore X Stroke:
80 mm x 78 mm
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 55-60 HP (est. at crank)
Torque:
Approx. 53-58 ft-lbs (est.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with 46mm throttle body
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Lubrication System
Oil Type:
SAE 10W-50 Synthetic (Polaris recommendation)
Oil Capacity:
Approx. 2.75 Quarts (2.6 Liters) with filter change
Ignition System
Spark Plug Type:
NGK CR9EB or equivalent
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT) with engine braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Optional Gearing:
N/A (standard configuration)
Features
Drive System:
Shaft Drive, On-Demand AWD
Final Drive:
Sealed shaft drive with front and rear differentials
Fluid Specifications
Gearcase Oil Type:
Polaris AGL High-Performance Gearcase Lubricant or equivalent SAE 75W-90 synthetic gear oil
Fluid Capacities
Gearcase Oil Capacity:
Approx. 0.4 Quarts (0.38 Liters)
📐 Dimensions
Exterior
Length:
85 in. (215.9 cm)
Width:
47.6 in. (120.9 cm)
Height:
50 in. (127 cm)
Wheelbase:
57 in. (144.8 cm)
Ground Clearance:
11.5 in. (29.2 cm)
Cargo
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Weights
Dry Weight:
Approx. 663 lbs (300.7 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Gvw:
1375 lbs (623.7 kg)
🛡️ Safety Features
Ratings
Safety Certification:
ATV Safety Institute (ASI) recommended practices apply
Active Features
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Dual 50W headlights, dual brakelights/taillights
Passive Features
Roll Over Protection:
N/A (ATV design)
Seat Belt:
N/A (ATV design, operator must use helmet and appropriate safety gear)
💡 Technology Features
Infotainment
Instrument Cluster:
Digital instrument cluster displaying speed, RPM, odometer, trip meters, fuel level, gear indicator, and diagnostic lights.
Driver Assistance
Traction Control:
N/A (On-Demand AWD provides automatic traction assist)
Connectivity
Diagnostic Port:
Diagnostic connector for EFI system and fault code retrieval.
🔧 Maintenance
Service Intervals
Initial Break In Service:
Recommended at 10 hours or 50 miles, involving oil change, filter change, and general inspection.
Regular Oil Change:
Every 100 hours or 6 months, whichever comes first.
Air Filter Cleaning Inspection:
Every 25 hours or 3 months.
Spark Plug Replacement:
Every 100 hours or 12 months.
Pvt Belt Inspection:
Every 50 hours or 6 months.
Fluid Specifications
Coolant Type:
Polaris Premium Pre-Mixed Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:
PVT belt wear, front differential bushings, wheel bearings, tie rod ends.
Efi Related:
Occasional issues with throttle position sensors or fuel injector clogging may require cleaning or replacement, detailed in the manual.
Suspension Wear:
Aggressive riding can lead to premature wear of A-arm bushings and ball joints, as well as shock absorber degradation.
📚 Vehicle History
Brand Heritage
Polarish Heritage:
Polaris has been a pioneer in the powersports industry since 1954, known for innovation in snowmobiles, ATVs, and motorcycles.
Model Evolution
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, emphasizing utility, comfort, and performance. The Touring models specifically cater to riders who prioritize comfort for longer rides or carrying a passenger.
800 Engine Introduction:
The 800cc V-twin engine was a significant upgrade in power and torque for the Polaris ATV lineup, offering a substantial performance boost over previous smaller displacement engines.
Production
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
🏆 Awards & Recognition
Recognitions
Atv Of The Year Nominations:
While specific awards for the 2009 model year are not readily available, the Polaris Sportsman line consistently receives positive reviews for its performance and utility from powersports publications.
Ratings
Consumer Reviews:
Owners generally praise the 800 EFI for its power, comfortable ride, and towing capability, while noting the importance of regular maintenance.
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