Polaris 800 Touring Sportsman 2008 Workshop Service Manual

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Taper: Atv

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UGS: 82680

Mots clés: 2008 800 Touring Sportsman ATV Misc Polaris Powersports

Variantes de produits

Description

The 2008 Sportsman 800 Touring is a robust All-Terrain Vehicle (ATV) designed for a blend of recreational riding, utility tasks, and trail performance. Featuring a powerful 799cc, liquid-cooled, V-twin engine with Electronic Fuel Injection (EFI) and a Continuously Variable Transmission (CVT), this ATV delivers reliable performance for demanding conditions. Its engineering emphasizes versatility, with independent front and rear suspension systems for enhanced stability and comfort, along with significant cargo capacity on both front and rear racks. The Sportsman 800 Touring is built to handle diverse terrains, making it a capable companion for both work and adventure. This comprehensive workshop service manual provides in-depth guidance for the maintenance, repair, and technical understanding of the 2008 Sportsman 800 Touring. It covers all essential systems, including the powertrain, chassis, fuel, cooling, brakes, and electrical components, detailing routine maintenance procedures, troubleshooting common issues, and offering step-by-step instructions for disassembly and reassembly. The manual includes critical technical specifications, torque values, and electrical diagrams, making it an indispensable resource for professional technicians and experienced owners seeking to ensure the optimal performance and longevity of their ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 800 Touring

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

Codes

Oem Manual Code:

Not specified in provided data

👋 Introduction

Market Position

Segment:

High-performance utility/sport ATV

Competitive Analysis

Competitors:

Can-Am Outlander, Arctic Cat 700, Yamaha Grizzly 700, Suzuki King Quad 750

Key Features

Versatility:

Designed for a blend of recreational riding, utility work, and trail performance.

Powertrain Emphasis:

Focus on the powerful 800cc V-twin engine and robust drivetrain.

Manual Purpose

Target Audience:

Primarily for mechanical technicians, but valuable for experienced ATV owners.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Page Count

Estimated Pages:

Typically 400-600 pages for a full workshop manual, specific count not provided.

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, drive axles, differential

Chassis:

Frame, suspension (front and rear), steering, wheels, tires

Electrical:

Ignition system, charging system, starting system, lighting, instrumentation, accessories

Fuel:

Fuel tank, fuel pump, fuel injection system (EFI), fuel filter

Cooling:

Radiator, fan, coolant system

Brakes:

Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads

Body:

Body panels, fenders, racks, seat, handlebars

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication, spark plug replacement, air filter cleaning/replacement, coolant checks

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable)

Disassembly Assembly:

Step-by-step instructions for component removal and reinstallation

Repair Rebuild:

Detailed instructions for repairing or rebuilding major components (engine, transmission, etc.)

Specifications Data:

Torque specifications, clearances, tolerances, fluid capacities, electrical diagrams

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution, designed for clear viewing and printing of diagrams and text.

Binding Type

Binding:

Not applicable (PDF Download)

Paper Type

Paper Type:

Not applicable (PDF Download)

Searchability

Text Search:

Typically searchable text within the PDF document.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, V-twin

Displacement:

799 cc (48.8 cubic inches)

Bore X Stroke:

89 mm x 64.5 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approximately 50-55 HP (estimated, official figures may vary)

Torque:

Approximately 45-50 ft-lbs (estimated, official figures may vary)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Ignition:

CDI (Capacitor Discharge Ignition)

Engine Management

Engine Control Unit (ECU) for fuel and ignition timing

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

Shaft Drive

Gear Selection:

High, Low, Neutral, Reverse, Park

Optional

Transfer Case:

2WD/4WD with Active Descent Control (ADC) and Polaris Variable Assist (PVA) steering, depending on trim/configuration.

Features

Clutch System:

Primary and secondary clutch system for CVT operation

Fluid Specifications

Cvt Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent

Fluid Capacities

Cvt Fluid Capacity:

Approximately 1.2 L (check manual for exact)

📐 Dimensions

Exterior

Length:

217.2 cm (85.5 inches)

Width:

116.8 cm (46 inches)

Height:

115.6 cm (45.5 inches)

Wheelbase:

133.4 cm (52.5 inches)

Ground Clearance:

27.9 cm (11 inches)

Cargo

Front Rack Capacity:

136 kg (300 lbs)

Rear Rack Capacity:

272 kg (600 lbs)

Weights

Dry Weight:

290 kg (640 lbs)

Towing Capacity:

680 kg (1,500 lbs)

Tires

Front Tire Size:

AT 25 x 8-12

Rear Tire Size:

AT 25 x 11-12

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI standards for recreational off-highway vehicles. (Note: ATVs are not designed for on-road use.)

Active Features

Braking System:

Hydraulic disc brakes (front and rear)

Engine Braking:

Integrated engine braking via CVT

Suspension System:

Independent Front Suspension (IFS) and Polaris Independent Rear Suspension (IRS) for improved stability and ride comfort.

Passive Features

Seat Belt Requirements:

Not applicable for this type of ATV; rider must wear a helmet and appropriate safety gear.

Lighting

Headlights:

Dual halogen headlights

Taillights:

LED taillight and brake light

💡 Technology Features

Infotainment

Instrumentation:

Digital instrument cluster displaying speed, RPM, fuel level, odometer, trip meter, 2WD/4WD indicator, gear indicator, etc.

Driver Assistance

Assist Systems:

Active Descent Control (ADC) for downhill control.

Connectivity

Charging Port:

12V accessory outlet for charging devices (check for model specifics).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first. (Refer to manual for exact interval)

Air Filter Cleaning:

Every 25 hours or more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 2 years or 100 hours. (Check manual for specific plug and gap)

Belt Inspection:

Inspect CVT belt at 50 hours for wear and damage. Replace as needed.

Fluid Specifications

Engine Oil Type:

SAE 0W-40 Synthetic (Polaris recommends their brand, but industry standards can be used if specified)

Coolant Type:

Ethylene Glycol based antifreeze (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Fluid Capacities

Engine Oil Capacity:

2.4 L (2.5 US qt) with filter change. (Check manual for exact)

Known Issues

Cvt Belt Wear:

CVT belts can wear and fail prematurely if subjected to excessive heat, overloading, or improper belt tension. Regular inspection is crucial.

Cooling Fan Failure:

Cooling fan motors can sometimes fail, leading to overheating. Check fan operation regularly.

Efi Sensor Issues:

EFI system sensors (e.g., TPS, MAP) can occasionally cause performance issues if they fail or become contaminated.

Suspension Component Wear:

Bushings and ball joints in the suspension can wear over time, leading to play and handling degradation.

📚 Vehicle History

Brand Heritage

Polarís History:

Polaris Inc. is a long-standing American manufacturer of powersports vehicles, known for its ATVs, snowmobiles, and motorcycles. Founded in 1954.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from basic utility models to more performance-oriented and feature-rich versions like the 800 Touring.

Production

Manufacturing Location:

USA (typically Polaris manufacturing facilities)

Production Years:

The 800 Sportsman platform was in production for several years, with the 2008 model representing a specific iteration.

🏆 Awards & Recognition

Recognitions

Atv Awards:

Specific awards for the 2008 Sportsman 800 Touring are not readily available, but Polaris ATVs have consistently received positive reviews and accolades for performance and innovation within the powersports industry.