🏷️ Basic Information

Make:

Polaris

Model:

Sportsman Touring 800 EFI

Model Year:

2009-2010

Product Identifier:

POLARIS SPORTSMAN TOURING 800 EFI Service Repair Manual PDF 2009-2010 Download

👋 Introduction

Category:

High-performance utility ATV (All-Terrain Vehicle)

Target Audience:

Recreational riders, utility users, hunters, and outdoor enthusiasts requiring a powerful and capable two-up ATV.

Segment:

Large-displacement, two-up utility ATV segment.

Key Competitors:

Can-Am Outlander MAX, Arctic Cat Thundercat, Yamaha Grizzly 700, Honda Foreman/Rancher (though often 1-up focused).

Seating:

Designed for two riders with a comfortable passenger seat and backrest.

Engine Power:

Class-leading 800cc V-twin engine for strong performance.

Suspension:

Independent front and rear suspension for superior ride quality and handling.

Storage:

Integrated front and rear racks for cargo hauling, often with sealed storage compartments.

📋 Manual Details

Vehicle Coverage:

2009-2010 Polaris Sportsman Touring 800 EFI models

Estimated Pages:

Hundreds of pages (specific number not provided, but implies comprehensive coverage)

Type:

Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, top end, bottom end, lubrication system, cooling system, fuel system, intake and exhaust systems.

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) service, belt replacement, clutch inspection, gearcase overhaul.

Drivetrain:

Front and rear drive systems, differential service, axle maintenance, driveshaft inspection.

Suspension:

Front and rear suspension components, shock absorber service and adjustment, control arm maintenance, bushing replacement.

Brakes:

Hydraulic brake system, brake fluid service, caliper and rotor inspection and replacement, bleeding procedures.

Electrical:

Wiring diagrams, battery service, charging system (stator, voltage regulator), ignition system, lighting, starter motor, EFI control module.

Fuel System:

EFI system, fuel pump, injectors, throttle body, fuel lines, fuel tank, pressure testing.

Cooling System:

Radiator service, coolant types and specifications, fan operation, thermostat replacement.

Chassis:

Frame inspection, body panel removal and installation, seat service, storage compartment maintenance.

Steering:

Steering column, tie rod ends, wheel alignment procedures, EPS (Electronic Power Steering) system if applicable (check specific model variant).

Maintenance:

Regular scheduled maintenance, fluid changes, filter replacements, lubrication points, pre-ride inspections.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, error code interpretation for EFI system.

Repair:

Detailed step-by-step instructions for component removal, repair, and reinstallation across all systems.

Rebuild:

Complete engine and transmission rebuild procedures, including torque specifications and component clearances.

Restoration:

Guidance for refurbishing and restoring worn or damaged components.

Torque Specifications:

All critical bolt and nut torque values for assembly and disassembly.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits.

Depth:

In-depth, comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts.

Scope:

Covers all aspects from routine maintenance to major component overhauls and diagnostics.

📊 Manual Specifications

Format:

PDF

Searchable:

Likely searchable text within the PDF (standard for professional manuals).

Quality:

High-resolution, clear images and text for easy readability and printing.

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

V-Twin, 4-Stroke, SOHC, 8-Valve

Displacement:

799cc (approximate)

Bore X Stroke:

Data not explicitly provided in description, but typical for 800cc V-twin.

Cooling System:

Liquid-cooled

Horsepower:

Estimated 50-60 HP (typical for this class and displacement)

Torque:

Estimated 50-60 lb-ft (typical for this class and displacement)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum recommended)

Fuel Capacity:

Approximately 4.0 gallons (15.1 L)

🔧 Transmission

Type:

Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Type:

N/A (PVT is standard for this model)

Clutching:

Dual centrifugal clutch system for seamless ratio changes.

Drive Modes:

On-Demand All-Wheel Drive (AWD) / 2WD selectable

Gear Reduction:

Gear reduction in front and rear final drives for increased torque.

📐 Dimensions

Length:

Approximately 85.2 inches (2164 mm)

Width:

Approximately 46 inches (1168 mm)

Height:

Approximately 48 inches (1219 mm)

Wheelbase:

Approximately 56.3 inches (1430 mm)

Ground Clearance:

Approximately 11.0 inches (279 mm)

Dry Weight:

Approximately 666 lbs (302 kg)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

Storage:

Front and rear steel racks with integrated tie-down points, often a sealed front storage bin.

🛡️ Safety Features

Atv Safety:

ATVs are inherently more dangerous than cars. Always follow safe operating practices. No official crash ratings like cars.

Braking:

Hydraulic disc brakes front and rear with parking brake mechanism.

Engine Braking:

Integrated engine braking system within the PVT for downhill control.

Throttle Control:

Thumb throttle with adjustable tension.

Handlebars:

Handlebar with handguards for protection.

Seat:

Ergonomic seating with passenger grab handles and backrest.

Lighting:

Dual headlights, taillight, and brake light.

💡 Technology Features

Display:

Digital instrument cluster providing speed, RPM, fuel level, gear indicator, odometer, trip meter, and warning lights.

Lighting System:

Halogen headlights for illumination, LED taillight/brake light.

Efi:

Electronic Fuel Injection (EFI) for optimized fuel and air delivery, improved throttle response, and cold-weather starting.

AWD:

On-Demand All-Wheel Drive (AWD) system that automatically engages front wheels when rear wheels lose traction.

Diagnostic Port:

Typically equipped with a diagnostic port for connecting specialized EFI diagnostic tools (e.g., Polaris Digital Wrench).

🔧 Maintenance

Oil Change Engine:

Every 100 hours or annually (refer to manual for precise interval, often 50/100 hours for ATVs).

Air Filter Cleaning:

Inspect every 50 hours or as needed in dusty conditions. Replace as required.

Spark Plug Replacement:

Recommended at 100 hours or annually.

Transmission Fluid Change:

Typically every 100-200 hours or annually, depending on usage. Refer to manual for PVT fluid specifications.

Brake Fluid Flush:

Recommended every 2 years or as needed if fluid appears contaminated.

Engine Oil:

Polaris PS-4 5W-50 Full Synthetic (or equivalent meeting API CI-4/SL specifications).

Engine Oil Capacity:

Approximately 2.1 quarts (2.0 liters) with filter change.

Transmission Differential Fluid:

Polaris Demand Drive Fluid (front differential) and Gearcase Lubricant (rear differential/gearcase). Specific viscosity grades will be in the manual.

Coolant:

50/50 mixture of ethylene glycol antifreeze and distilled water.

Efi System:

Potential for sensor failures (e.g., throttle position sensor), injector clogging, or idle control issues. Requires diagnostic tool for precise troubleshooting.

Pvt Belt:

PVT belt wear and potential breakage with aggressive riding or improper maintenance. Regular inspection is crucial.

Suspension Bushings:

Wear in control arm bushings can lead to premature tire wear and steering looseness.

Charging System:

Stator or voltage regulator failures can lead to battery not charging, requiring testing and replacement.

Cooling Fan:

Fan switch or motor failure can lead to overheating, especially during slow-speed operation.

📚 Vehicle History

Manufacturer:

Polaris Industries, an American manufacturer known for powersports vehicles, including ATVs, snowmobiles, and motorcycles.

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from utility-focused models to more performance-oriented and versatile machines.

Touring Variant:

The 'Touring' designation signifies models specifically designed for two-up riding, often with enhanced comfort and passenger amenities.

Production Years:

2009-2010 model years, likely part of a broader generation of 800cc Sportsman models.

🏆 Awards & Recognition

Powersports Awards:

While specific awards for this exact model year are not detailed in the product description, Polaris Sportsman models have historically received positive reviews for their utility, comfort, and performance in industry publications.