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POLARIS SPORTSMAN TOURING 800 EFI INTERNATIONAL Full Service & Repair Manual 2009-2010

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The Polaris Sportsman Touring 800 EFI International, produced for the 2009 and 2010 model years, represents a robust and versatile all-terrain vehicle designed for both recreational trail riding and demanding...
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Type: Atv
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Sku: 58151
POLARIS SPORTSMAN TOURING 800 EFI INTERNATIONAL Full Service & Repair Manual 2009-2010POLARIS SPORTSMAN TOURING 800 EFI INTERNATIONAL Full Service & Repair Manual 2009-2010POLARIS SPORTSMAN TOURING 800 EFI INTERNATIONAL Full Service & Repair Manual 2009-2010
The Polaris Sportsman Touring 800 EFI International, produced for the 2009 and 2010 model years, represents a robust and versatile all-terrain vehicle designed for both recreational trail riding and demanding utility tasks. Featuring a powerful 799.7 cc V-twin engine with Electronic Fuel Injection (EFI) for enhanced performance and efficiency, this model is engineered for comfort and capability. Its extended chassis accommodates a passenger, offering a comfortable touring experience, complemented by Independent Rear Suspension (IRS) for stability. With ample cargo capacity on its front and rear racks and a substantial towing capability of 1500 lbs, the Sportsman Touring 800 EFI is built to handle diverse off-road environments and carry necessary equipment. This comprehensive Factory Service & Repair Workshop Manual provides in-depth guidance for the maintenance, repair, and troubleshooting of your Polaris Sportsman Touring 800 EFI. Covering all essential systems, including the V-twin EFI engine, transmission, braking, suspension, and electrical components, this manual details everything from routine preventative maintenance schedules and fluid specifications to major repair procedures and diagnostics. Its extensive content, presented in English, is designed to assist owners, mechanics, and technicians in keeping the vehicle in optimal condition, ensuring reliability and performance through clear instructions, high-resolution diagrams, and systematic troubleshooting charts.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman Touring 800 EFI
Model Variant:
International
Years Covered:
2009, 2010
Codes
Engine Code:
V-Twin EFI
👋 Introduction
Market Position
Category:
High-performance, multi-terrain ATV
Target Audience:
Recreational riders, utility users, off-road enthusiasts seeking touring capability.
Competitive Analysis
Competitors:
Can-Am Outlander, Arctic Cat Thundercat, Yamaha Grizzly.
Key Features
Engine Power:
Torquey 800cc V-twin engine.
Touring Comfort:
Extended chassis for passenger comfort, comfortable seating, ample storage.
Versatility:
Capable for both recreational trail riding and utility tasks.
Efi Technology:
Electronic Fuel Injection for improved throttle response, fuel efficiency, and cold-weather starting.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service & Repair Workshop Manual
Language:
English
Format:
PDF Download
Coverage Scope:
Full Service, Repair, Maintenance, Troubleshooting, Diagnostics
Delivery Method:
Instant Download
Page Count
Page Count Estimated:
Extensive (Full Factory Documentation)
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, fuel pressure regulation.
Cooling System:
Radiator, fan, thermostat, coolant flow, flushing, and filling procedures.
Exhaust System:
Muffler, catalytic converter, exhaust pipe inspection and replacement.
Transmission Drivetrain:
PVT (Polaris Variable Transmission) belt inspection/replacement, clutch service, final drive, AWD system.
Suspension Steering:
Front and rear suspension components, shocks, bushings, steering linkage, tie rods, wheel alignment.
Braking System:
Hydraulic disc brakes, brake pad replacement, caliper service, bleeding procedures, master cylinder.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, wiring diagrams.
Chassis Frame:
Frame inspection, body panel removal/installation, seat, racks, fenders.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), fault finding procedures.
Procedures Included
Preventative Maintenance:
Regular service intervals, fluid changes, filter replacements, lubrication points.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension overhauls, electrical system troubleshooting.
Component Replacement:
Detailed instructions for replacing virtually all components.
Troubleshooting Charts:
Systematic approach to diagnosing and resolving common and uncommon issues.
Technical Depth
Depth Level:
Comprehensive Factory Level Detail
Detail Level:
Suitable for professional technicians and advanced DIY mechanics.
Diagnostic Tools:
Information on using diagnostic tools and interpreting data.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations.
Print Capability:
Printable pages for hands-on use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, V-twin
Displacement:
799.7 cc (48.8 cu. in.)
Bore X Stroke:
90.0 mm x 62.5 mm (3.54 in. x 2.46 in.)
Cooling System:
Liquid-cooled
Performance
Horsepower Est:
Approx. 53 HP (at crankshaft)
Torque Est:
Approx. 47.5 lb-ft (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Fuel Capacity:
4.5 gal (17.0 L)
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT) with engine braking
Transmission Gear Selection:
Automatic (H, L, N, R, P)
Features
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/AWD selector
Final Drive:
Sealed, single-stage, with metal gear reduction
📐 Dimensions
Exterior
Length:
85 in. (215.9 cm)
Width:
46 in. (116.8 cm)
Height:
50.5 in. (128.3 cm)
Wheelbase:
57 in. (144.8 cm)
Ground Clearance:
11.5 in. (29.2 cm)
Cargo
Front Rack Capacity:
100 lbs (45.4 kg)
Rear Rack Capacity:
200 lbs (90.7 kg)
Weights
Dry Weight:
691 lbs (313.4 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Hitch Receiver Size:
2 in.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Meets ANSI standards for recreational ATVs.
Active Features
Braking System:
Hydraulic disc brakes front and rear; Engine braking.
Drive Mode:
On-Demand AWD for enhanced traction.
Passive Features
Chassis Design:
Rolled Independent Rear Suspension (IRS) for stability and comfort.
Lighting:
Dual headlights, dual taillights/brake lights.
Operator Positioning:
Ergonomic controls and comfortable seating position.
💡 Technology Features
Infotainment
Display Features:
Digital instrument cluster displaying speed, RPM, fuel level, gear indicator, AWD status, etc.
Lighting Technology:
Halogen headlights, LED taillights/brake lights.
Driver Assistance
Traction Control:
On-Demand AWD system.
Engine Braking:
Integrated engine braking system (EBS) on PVT for controlled descents.
Connectivity
Accessory Power:
Standard 12V DC outlet for charging accessories.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first.
Air Filter Inspection:
Inspect every 50 hours or monthly; clean/replace as needed.
Spark Plug Replacement:
Replace every 100 hours or 12 months.
Pvt Belt Inspection:
Inspect every 200 hours or 12 months.
Brake Fluid Flush:
Flush and replace every 24 months.
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris PS-4)
Engine Oil Capacity:
2.1 US qt. (2.0 L)
Coolant Type:
Polaris Coolant or equivalent ethylene glycol-based antifreeze (50/50 mix).
Brake Fluid Type:
DOT 4
Transmission Fluid Type:
SAE 0W-40 Synthetic (Polaris PS-4)
Known Issues
Common Wear Items:
PVT belt, suspension bushings, tie rod ends, wheel bearings.
Efi System Considerations:
Regular cleaning of throttle body and checking for vacuum leaks can prevent performance issues.
Electrical System Notes:
Check battery terminals for corrosion; ensure proper voltage regulation.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
United States
Brand Focus:
Polaris is a well-established manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Model Evolution
Sportsman Lineup:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, capability, and ruggedness.
Touring Variant Introduction:
The Touring models were developed to enhance rider and passenger comfort for longer journeys.
Production
Production Years For Model:
2009-2010 (specific to this manual's coverage)
Manufacturing Locations:
Primarily manufactured in the USA.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Polaris Sportsman models have consistently received positive reviews for their comfort, handling, and utility.
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