Polaris Sportsman 800 EFi Touring ATV Complete Workshop Service Repair Manual 2008 2009

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Tipo: Atv

Proveedor:

SKU: 91732

Etiquetas: 2008 2009 ATV Misc Polaris Powersports Sportsman 800 EFi Touring

Variantes de producto

Descripción

The Polaris Sportsman 800 EFi Touring is a premium two-up recreational All-Terrain Vehicle (ATV) designed for off-road enthusiasts who prioritize comfort, power, and the ability to carry a passenger on extended rides. Covering the 2008 and 2009 model years, this ATV is equipped with a potent 795cc liquid-cooled, 4-stroke SOHC twin-cylinder engine featuring Electronic Fuel Injection (EFI) for reliable performance. Its engineering is characterized by an Independent Front and Rear Suspension (IRS) for superior ride quality, an automatic Variable Transmission (PVT) with High/Low range and reverse, and On-Demand True All-Wheel Drive (AWD) for exceptional traction. The 2-up seating configuration, complete with passenger floorboards and a backrest, enhances rider and passenger comfort, making it ideal for exploring challenging terrain or undertaking longer journeys. This comprehensive Workshop Service Repair Manual provides essential information for maintaining and repairing your Polaris Sportsman 800 EFi Touring. It covers all critical systems in detail, including the engine, fuel system, ignition, cooling, transmission, suspension, brakes, steering, and electrical systems. The manual offers step-by-step procedures for scheduled maintenance, troubleshooting common and complex issues, component repair, rebuilds, and adjustments. With high-resolution images, clear diagrams, and searchable text, this English-language manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 800 EFi Touring

Model Variant:

Touring

Model Years Covered:

2008, 2009

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Engine Identifier:

800 EFi (Electronic Fuel Injection)

👋 Introduction

Market Position

Segment:

Premium 2-up recreational ATV

Target Audience:

Off-road enthusiasts seeking comfort, power, and the ability to carry a passenger for extended rides.

Competitive Analysis

Competitors:

Can-Am Outlander MAX, Arctic Cat Prowler XT, Yamaha Grizzly 700 (though Grizzly is typically 1-up, touring variants exist).

Key Features

Engine:

Powerful 800cc V-twin, liquid-cooled, 4-stroke, SOHC, EFI

Seating:

2-up seating configuration with passenger backrest and floorboards

Suspension:

Independent Front and Rear Suspension (IRS) for superior ride quality

Transmission:

Automatic PVT (Polaris Variable Transmission) with High/Low range and reverse

On-Demand True All-Wheel Drive (AWD)

📋 Manual Details

Coverage Areas

Language:

English

Format:

Downloadable PDF

Coverage Scope:

Complete Workshop Service Repair

Page Count

Estimated Pages:

Extensive (typically 500+ pages for comprehensive ATV manuals)

Manual Type

Type:

Workshop Service Repair Manual

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, diagnostics, troubleshooting, and overhaul of the 800cc EFi engine.

Fuel System:

EFI system components, fuel pump, injectors, throttle body, sensors, ECU diagnostics, and tuning.

Ignition System:

Spark plugs, ignition coils, CDI unit, troubleshooting ignition faults.

Cooling System:

Radiator, fan, coolant, thermostat, water pump, maintenance and repair.

Transmission Drivetrain:

PVT (Polaris Variable Transmission) system (clutch operation, belt replacement), final drive, driveshafts, differentials, and CV joints.

Suspension:

Front and rear suspension components, shocks, springs, A-arms, bushings, alignment, and adjustments.

Brakes:

Hydraulic brake system, master cylinders, calipers, brake lines, pads, rotors, bleeding procedures, and parking brake.

Steering System:

Handlebar assembly, steering post, tie rods, steering mechanism, and potential for EPS (Electronic Power Steering) system coverage if equipped.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, fuses, relays, and diagnostic codes.

Chassis Frame:

Frame inspection, component mounting, and general chassis integrity.

Bodywork Plastics:

Body panel removal, installation, and care.

Procedures Included

Maintenance:

Scheduled maintenance tasks, lubrication points, filter changes, fluid checks, and adjustments.

Troubleshooting:

Systematic diagnostic procedures for common and complex issues, including error code interpretation.

Repair:

Step-by-step instructions for component removal, repair, replacement, and reassembly.

Rebuilds:

Complete engine and transmission overhaul procedures.

Adjustments:

Carburetor (if applicable, though EFi is specified), throttle cable, clutch, and suspension adjustments.

Technical Depth

Depth:

Comprehensive, covering everything from basic user maintenance to full mechanical and electrical diagnostics and repairs.

Diagnostic Tools:

Information on using diagnostic tools or reading diagnostic trouble codes (DTCs) for the EFi system.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for on-site workshop use.

Print Quality

Quality:

High-resolution images, diagrams, and clear text.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-Cooled, 4-Stroke, SOHC Twin Cylinder

Displacement:

795cc

Bore X Stroke:

90 mm x 62.5 mm (Typical for this engine family)

Horsepower:

Approximately 55-60 HP (Varies slightly by specific tuning)

Torque:

Approximately 45-50 lb-ft (Varies slightly by specific tuning)

Performance

Compression Ratio:

9.5:1 (Typical)

Top Speed:

Governed and varies, typically around 60-65 mph (100-105 km/h)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (91 Octane Recommended)

Fuel Tank Capacity:

5.25 US gal (19.9 L)

🔧 Transmission

Standard

Type:

Automatic Polaris Variable Transmission (PVT)

Gear Selection:

Park, Reverse, Neutral, Low, High

Drive System:

Shaft Drive with On-Demand True All-Wheel Drive (AWD)

Optional

Type:

N/A (PVT is standard)

Features

Clutch:

Primary and Secondary Clutch System

Transmission Fluid:

Polaris AGL Synthetic Gearcase Lubricant (or equivalent meeting specifications)

📐 Dimensions

Exterior

Length:

85.2 in (2164 mm)

Width:

46 in (1168 mm)

Height:

47.2 in (1199 mm)

Wheelbase:

56.5 in (1435 mm)

Ground Clearance:

11.5 in (292 mm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Weights

Dry Weight:

662 lbs (300 kg)

Towing Capacity:

1,500 lbs (680 kg)

Payload Capacity:

475 lbs (215 kg)

🛡️ Safety Features

Ratings

Rollover Protection:

N/A (ATVs are not typically crash-rated like cars; focus is on operator protection and stability)

Active Features

Braking:

Hydraulic disc brakes, engine braking via PVT

Traction Control:

On-Demand True AWD

Passive Features

Lighting:

Dual 50W Halogen headlights, LED tail/brake light

Operator Controls:

Ergonomically placed controls, hand guards (often standard)

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, trip meter, fuel gauge, gear indicator, AWD indicator, clock). No advanced infotainment system typically.

Driver Assistance

Features:

Engine braking, On-Demand AWD, power steering (if equipped on specific Touring trims).

Connectivity

Features:

N/A (No Bluetooth, USB, or smartphone integration on this model year)

🔧 Maintenance

Service Intervals

Oil Change:

Every 100 hours or 12 months, whichever comes first (check manual for specifics)

Air Filter:

Inspect every 50 hours, clean/replace as needed

Spark Plug:

Replace every 100 hours or 12 months (or as specified)

Belt Inspection:

Inspect PVT belt at 50 hours, replace based on wear

Brake Fluid:

Flush and replace every 24 months (or as specified)

Fluid Specifications

Engine Oil:

Polaris PS-4 10W-50 Full Synthetic (or equivalent API SG/SH/SJ rated)

Engine Oil Capacity:

Approx. 2.5 US qts (2.4 L) with filter change

Transmission Gearcase Oil:

Polaris AGL Synthetic Gearcase Lubricant (or equivalent)

Transmission Gearcase Capacity:

Approx. 10 oz (0.3 L)

Coolant:

50/50 mixture of Polaris Premium All-Season Coolant and distilled water (or equivalent ethylene glycol based)

Known Issues

Common Wear Items:

PVT belt, suspension bushings, tie rod ends, ball joints, wheel bearings.

Efi Diagnostics:

Occasional sensor issues (e.g., TPS, MAP sensor) requiring diagnostic tool access.

Charging System:

Stator or regulator/rectifier failures can occur over time, impacting battery charging.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc.

Founding Year:

Specialty:

Pioneer in snowmobiles and ATVs, known for innovation in off-road vehicles.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving with increased power, comfort, and technology over the years.

Touring Variant:

The Touring models specifically cater to riders who prioritize passenger comfort and longer-distance capability.

Production

Manufacturing Location:

Primarily USA (e.g., Roseau, Minnesota)

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Polaris Sportsman line consistently receives positive reviews and awards for performance, comfort, and utility from off-road publications.

Ratings

Rider Satisfaction:

High rider satisfaction due to its powerful engine and comfortable ride, especially for 2-up touring.

Certifications

Safety Standards:

Complies with ANSI standards for recreational off-highway vehicles.