2009 Polaris Sportsman 800 EFI, X2 & Touring ATV Service & Repair Manual (P/N 9921795)

This Polaris service manual (P/N 9921795) covers the 2009 Sportsman 800 EFI, Sportsman X2 800 EFI and Sportsman Touring 800 EFI, including the Touring International configuration.

Searchable Service Text and Wiring Diagram Access

Search, bookmarks and diagram detail: The main service text is searchable, and embedded PDF bookmarks cover the service chapters, International supplement and wiring section. Many labels within circuit drawings are not searchable. Small wiring labels require zooming; fine circuit lines can appear light in full-page view.

One printable, English-language, 386-page PDF contains 366 pages of main chapters, a six-page Touring International supplement and a 14-page wiring section. Seven notes pages and one intentionally blank page are already included in these totals.

Engine, EFI and Drivetrain Service

These selected service topics outline the repair coverage rather than reproduce the complete contents. Other subjects include winch operation and preparation for vehicle storage.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head disassembly, valve-seat reconditioning, piston inspection and crankcase disassembly and reassembly.

• EFI diagnosis: Fuel-pump testing, injector checks, sensor diagnosis, TPS replacement and calibration, with diagnostic blink codes and related circuit diagrams.

• PVT and EBS: Drive and driven clutch service, belt inspection, clutch alignment and offset checks, plus PVT sealing and ducting components.

• Final drive and transmission: CV joint and boot service, ADC gearcase overhaul, hydraulic-circuit bleeding and separate gearbox procedures for Sportsman and X2/Touring configurations.

• Brakes and chassis: Steering-post service, front strut replacement, suspension assembly information, caliper rebuilding, brake bleeding and component service limits.

• Electrical troubleshooting: Instrument-cluster tests, AWD and ADC circuit checks, charging-system diagnosis, starter testing and model-specific wiring diagrams.

The repair sections suit technicians with established ATV service skills and suitable test equipment; the manual specifically assigns PVT maintenance and repair to properly trained Polaris Master Service Dealer technicians.

Component and Engine Maintenance

The periodic maintenance chart supports routine upkeep and repair planning, with service intervals for the transmission, cooling system and gearcases. Air-box inspection, cooling-system pressure testing and coolant bleeding are also covered.

Engine repair information extends to hydraulic-lifter inspection, camshaft and bearing checks, cylinder honing, and crankcase and cylinder-head fastener torque patterns. The Oil Flow Chart traces the lubrication circuit through the engine, helping relate internal oil passages to the components they supply.

The valve-seat section recommends specialist machine-shop work and identifies the cylinder-head valve guides as nonreplaceable. Water-pump service notes explain how lubricating the mechanical seal can prevent proper sealing and how attempting seal replacement with the gear/stator housing attached can damage the shaft.

EFI Testing and Calibration Limits

Fuel-system layouts and sensor descriptions connect the diagnostic blink-code chart with the components being tested. TPS procedures identify tester adapter harness PU-47082, while fuel-delivery diagnosis includes pressure testing and pump/tank assembly replacement.

T-BAP sensor testing is assigned to dealer diagnostic software, with operating instructions referred to a separate EFI Diagnostic Software Manual. The throttle-body warning distinguishes TPS calibration from the factory-set stop screw: changing that screw requires replacement of the throttle-body assembly.

PVT, ADC and Gearbox Differences

EBS clutch illustrations show the one-way clutch arrangement, while belt-condition checks and the PVT problem, cause and remedy chart support investigation of slipping, overheating and engagement complaints.

The ADC Gearcase Exploded View accompanies internal inspection, piston replacement and reassembly information. Separate transmission sections distinguish the standard Sportsman gearbox from the X2/Touring unit, including the latter’s front-output-shaft backlash procedure and specified backlash-setting tool 2871695.

Chassis, Electrical and International Equipment

Brake coverage distinguishes the rear caliper arrangements and includes bore inspection, seal replacement and bleeding procedures. Chassis illustrations also separate the standard rear suspension from the X2/Touring assembly.

The Charging System Testing Flow Chart, Starter System Testing Flow Chart and electrical Troubleshooting Diagrams organize fault isolation by circuit. Wiring diagrams distinguish standard, X2/Touring, Touring International and ADC circuits.

The International supplement explains the Touring model’s integrated hand- and foot-brake circuits, steering lock and Turn / Hazard Signal Diagram. These details help identify the appropriate brake and electrical information before selecting a procedure.

Securely support the ATV and follow the manual’s electrical-isolation instructions before disassembly.

Examples of Engine and TPS Reference Data

Engine checks: EH076OLE specifications list an idle speed of 1150 ± 100 RPM and compression pressure of 150–200 psi. The compression-test section explains that readings vary with cranking speed.

TPS calibration: The throttle-position-sensor adjustment section specifies an output of 0.735 ± 0.010 Vdc with the throttle body fully closed.