2009 Polaris Sportsman 800 EFI Service Repair Workshop Manual Download PDF
Codes
Engine Code:
800cc, Liquid-Cooled, 4-Stroke, SOHC, V-Twin EFI
👋 Introduction
Market Position
Market Segment:
High-performance All-Terrain Vehicle (ATV) segment, known for its utility and off-road capabilities.
Competitive Analysis
Competitors 2009:
Key competitors in this era included models from Yamaha (Grizzly 700), Can-Am (Outlander 800), and Arctic Cat (Thundercat 1000).
Key Features
Vehicle Highlights:
Powerful V-twin engine, electronic fuel injection (EFI) for improved performance and cold starts, independent rear suspension (IRS) for enhanced ride quality, selectable 2WD/4WD with Polaris's on-demand AWD system, power steering on many models, and extensive accessory integration.
Comprehensive, from basic maintenance and adjustments to complex engine and electrical system repairs, including detailed diagnostic flowcharts and specifications.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, designed for clarity with detailed diagrams and text.
Print Quality
Printability:
All pages are printable for convenient workshop use.
Approximately 0.25 US quarts (0.24 Liters) for front and rear gearcases (check manual for exact amounts).
📐 Dimensions
Exterior
Length:
Varies by model (e.g., Sportsman 800 HO EFI: approx. 81.8 in / 207.8 cm; Sportsman Touring 800 EFI: approx. 85 in / 215.9 cm)
Width:
Varies by model (e.g., Sportsman 800 HO EFI: approx. 46 in / 116.8 cm)
Height:
Varies by model (e.g., Sportsman 800 HO EFI: approx. 48 in / 121.9 cm to seat)
Weights
Dry Weight:
Varies by model (e.g., Sportsman 800 HO EFI: approx. 650 lbs / 295 kg)
Ground Clearance:
Approximately 11.5 in / 29.2 cm (Varies by model and suspension setting)
Cargo
Front Rack Capacity:
Approx. 100 lbs / 45 kg
Rear Rack Capacity:
Approx. 200 lbs / 90 kg
Towing
Towing Capacity:
Approx. 1,500 lbs / 680 kg
Tires
Front Tire Size:
26 x 8-12 (Standard, varies by trim)
Rear Tire Size:
26 x 10-12 (Standard, varies by trim)
🛡️ Safety Features
Ratings
Safety Certification:
All Polaris ATVs are designed for off-road use and are not street legal unless specifically modified and registered for such use in applicable jurisdictions.
Active Features
Braking System:
Hydraulic disc brakes front and rear, single lever front and right rear brake, foot pedal rear brake.
ATVs are subject to specific safety warnings and riding guidelines. Always wear a helmet, eye protection, and appropriate clothing.
💡 Technology Features
Infotainment
Instrumentation:
Digital instrument cluster providing speed, RPM, odometer, trip meter, fuel level, gear indicator, AWD status, and diagnostic indicators.
Driver Assistance
Efi Benefits:
Electronic Fuel Injection provides precise fuel metering, leading to improved throttle response, better fuel efficiency, easier cold starts, and consistent performance at varying altitudes.
Connectivity
Accessory Integration:
Polaris factory accessories, such as winches, plow systems, lighting, and storage, are designed for seamless integration.
🔧 Maintenance
Service Intervals
Initial Break In:
Typically 10 hours or 100 miles, involving reduced load and oil change.
Engine Oil Change:
Every 100 hours or 1000 miles, or annually (whichever comes first).
Air Filter Cleaning:
Every 50 hours or 500 miles, or more frequently in dusty conditions.
Spark Plug Replacement:
Refer to manual, typically every 1-2 years or specified hours.
Fluid Specifications
Coolant Type:
Polaris All-Season Premium Antifreeze (or equivalent ethylene glycol-based coolant with corrosion inhibitors) mixed 50/50 with distilled water.
Known Issues
Common Wear Items:
Drive belts (PVT), wheel bearings, ball joints, tie rod ends, brake pads, and suspension bushings are common wear items that require regular inspection and replacement based on usage.
Efi Maintenance:
Keeping the fuel system clean and using fresh fuel is important for optimal EFI performance. Periodic injector cleaning might be beneficial.
📚 Vehicle History
Brand Heritage
Polarís Origin:
Polaris Industries Inc. was founded in 1954 and has a long history of innovation in powersports vehicles, including snowmobiles and ATVs.
Model Evolution
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, utility, and capability in various terrains since its introduction.
Production
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Atv Industry Recognition:
Polaris Sportsman models have historically received positive reviews for their versatility, comfort, and off-road prowess from automotive and powersports publications.
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