2009 Polaris Sportsman 6x6 800 EFI, Sportsman X2 & Sportsman Touring ATV Service Manual

Wiring diagrams, specifications, and repair sequences for Polaris Sportsman 6x6 800 EFI, Sportsman X2 & Sportsman Touring ATVs: engine, fuel system, electrical, drivetrain, and more. A09CL76AA

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Polaris Models Covered & Key Technical Specifications

Models: Sportsman 6x6 800 EFI, Sportsman X2, Sportsman Touring
Sub-models / Variants: 6x6, X2, Touring
Build Years: 2009
Serial Numbers: A09CL76AA
Technical Data:

  • Engine displacement: 760 cc
  • Engine type: Polaris Twin Cylinder, 4-stroke, Liquid Cooled
  • Number of cylinders: 2
  • Compression pressure: 150-200 psi
  • Idle speed: 1150 ± 100 RPM
  • Transmission type: Drumshift H/L/N/Rev/Park
  • Fuel system: Electronic Fuel Injection
  • Coolant system capacity: 3.6 qt (3.4 ltr)
  • Spark plug gap: 0.035 in. (0.9 mm)
  • Front gearcase lubricant capacity: 9.3 oz. (275 ml)
  • Drive system: PVT with EBS
Technical Specifications
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Document Number / Seller:
32066 / Betty Wilson
File Size:
10.26 MB
File Type:
PDF
Language:
English
Pages:
322
Printable:
Yes
Category:
6x6
Last updated / verified
Dec 22, 2025

Polaris Manual Features & Content Preview

Inside the 2009 Polaris Sportsman 6x6 800 EFI Service Manual

  • Covers 2009 Polaris Sportsman 6x6 800 EFI, Sportsman X2, and Sportsman Touring, including engine, drivetrain, and chassis documentation
  • Official Polaris publication P/N 9922030, first edition 2009
  • Contains 56 exploded-view diagrams, 6 detailed torque-specification tables, and 12 procedure-specific maintenance charts
  • Delivered as a direct download the moment payment clears
  • Full-text search finds any part number in seconds
  • Laid out for standard letter and A4 printing
  • This 322-page factory publication provides the complete technical foundation for the 2009 Polaris Sportsman 800 EFI engine build and chassis maintenance.

Engine and Drivetrain Walkthrough

The 2009 Polaris Sportsman 6x6 800 EFI service manual details engine removal, disassembly, and reassembly. Chapters cover cylinder head inspection, valve seat reconditioning, and crankshaft assembly, alongside troubleshooting for the electronic fuel injection system and cooling system air-bleeding procedures. Comprehensive exploded views document the crankcase, starter, flywheel, and oil system components to assist in parts identification and assembly alignment.

Maintenance and Technical Data

This 2009 Polaris Sportsman 800 EFI publication includes a detailed periodic maintenance chart and fluid-capacity specifications for the front, middle, and rear gearcases. The manual documents torque values for critical fasteners including cylinder head bolts and tie rod jam nuts. Cylinder head warp limit is listed at 0.004" (0.10 mm) in the engine specification table. Camshaft end play for the 2009 Polaris Sportsman 800 EFI is documented at 0.0167" ± 0.0098" in the engine service data. Engine idle speed for the 2009 Polaris Sportsman 800 EFI is specified at 1150 ± 100 RPM.

An official 322-page Polaris OEM workshop manual covering the 2009 Polaris Sportsman 6x6 800 EFI, Sportsman X2, and Sportsman Touring, documenting engine, chassis, electrical, and drivetrain specifications for the A09CL76AA build.

Manual FAQ, Purchase & Download Details

Does this manual include fluid capacities and lubricant charts for the Sportsman 6x6 800 EFI? keyboard_arrow_down

Manual includes comprehensive specification tables listing fluid capacities and approved lubricant types for the engine, transmission, and gearcases.

What information is included in the specification tables and technical reference charts for the 2009 Sportsman models? keyboard_arrow_down

These tables contain essential reference data including engine displacement, compression pressure ranges, and torque specification guidelines. The document also provides decimal equivalent charts and metric conversion tables.

Which sections reference electrical system wiring and connector identification? keyboard_arrow_down

Manual includes electrical sections that list circuit breaker specifications, alternator output data, and connector grease recommendations.

Can I see the chapter scope for major mechanical systems such as the engine and transmission? keyboard_arrow_down

Document structure covers major systems including the drivetrain, steering, suspension, and braking systems. Detailed chapters organize these topics for identification and system reference.

Is there a lookup section or glossary that defines the technical terms used in the manual? keyboard_arrow_down

Manual contains a dedicated glossary of terms to define abbreviations and concepts used throughout the text. It also includes identification guides for serial numbers and model designations. These reference artifacts assist in understanding the terminology specific to the 2009 Sportsman series.

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