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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Models Covered & Key Technical Specifications
Essential Engineering Factory Manual: 6x6 Professional Repair Handbook: Polaris Sportsman 6x6 800 EFI, Sportsman X2 & Sportsman Touring ATV (2009) Chassis-Documentation Year-Coverage 2009 | Model-Portfolio Sportsman 6x6 800 EFI, Sportsman X2, Sportsman Touring | Procedure-Type Service Manual
- Reference DPI Rating: 1200 dpi establishes the maximum print output Architecture.
- Approved Fastening Values: 150-200 psi signifies the recommended compression pressure range.
- Designated Fluid Capacity: 9.3 oz. is the front gearcase lubricant capacity.
- Essential End Play: 0.0167" ± 0.0098" defines the camshaft end play specification.
- Baseline Cooling Specs: 3.6 qt. is the liquid cooling system capacity.
- Fundamental Resolution Data: 800 RPM is the specified engine idle speed.
Manual Description & Preview
Essential Engineering Factory Manual: 6x6 Professional Repair Handbook: Polaris Sportsman 6x6 800 EFI, Sportsman X2 & Sportsman Touring ATV (2009) Chassis-Documentation
Year-Coverage: 2009 // Model-Portfolio: Sportsman 6x6 800 EFI, Sportsman X2, Sportsman Touring // Procedure-Type: Service Manual Logic
Technical Specifications Overview
| Integrated-Framework | System-Path | Calibration-Spec |
|---|---|---|
| Engine Specs | Cylinder Bore | 3.1495" (80 mm) |
| Drive Clutch | Spring Free Length | 2.92" (White) |
| Transmission | Capacity | 17.2 oz. (510 ml) |
| Fuel System | Idle Speed | 1150 ± 100 RPM |
| Front Gearcase | Lubricant Capacity | 9.3 oz. (275 ml) |
| Suspension | Ground Clearance | 10.50 in. (26.67 cm) |
Diagnostic procedures address engine performance and system checks. This manual covers comprehensive service for the 2009 Polaris Sportsman 6x6 800 EFI, Sportsman X2, and Sportsman Touring ATVs. It details component identification, maintenance schedules, and lubrication requirements.
Engine System Maintenance
Fundamentally calling for detailed procedures on engine removal and installation, cylinder inspection, and crankshaft assembly. It documents torque specifications for various engine components to ensure proper bolt stretch prevention.
Drivetrain Component Service
This section outlines the service procedures for the drive clutch, driven clutch, and drive belt. It includes inspection guidelines, disassembly, and reassembly instructions for the PVT system to maintain optimal performance.
Chassis and Suspension Systems
Covers the maintenance and repair of the ATV's chassis, including steering, front and rear suspension components, and wheel hub assemblies. Detailed procedures ensure vehicle stability and handling.
Troubleshooting and Diagnostics
Provides systematic diagnostic procedures for common issues, including EFI system troubleshooting and blink code interpretation, aiding in efficient problem resolution.
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