2009 Polaris Sportsman 6x6 800 EFI, Sportsman X2 & Sportsman Touring ATV Service Manual (P/N 9922233, 9922030)

This 322-page PDF is the Polaris service manual for the 2009 Sportsman 6x6 800 EFI, machine designation A09CL76AA (the model table lists A09CL76A), with the EH076OLE liquid-cooled twin-cylinder engine, Bosch electronic fuel injection, drum-shift H/L/N/Reverse/Park transmission, PVT with Engine Braking System (EBS), and Active Descent Control (ADC). It is suited to professional technicians and experienced owners who can work from torque sequences, service limits, electrical test data, and special-tool callouts; EFI work that depends on Polaris Digital Wrench requires dealer-level software and equipment.

• Document and model coverage: 322 PDF pages total - 318 numbered service pages in ten chapters plus WD-1 through WD-4. WD-4 is intentionally blank. X2 and Touring references are limited to shared component-location and EFI service notes; this is not an X2 or Touring repair manual.
• Engine repair: Covers engine removal and installation notes, cooling-system pressure testing and air bleeding, oil-pressure testing, cylinder honing, cylinder-head and valve service, valve-seat reconditioning, piston and crankshaft inspection, crankcase disassembly, and full reassembly.
• EFI and electrical diagnosis: Details fuel-pump and regulator tests, injector service, CPS, T-BAP, TPS, and coolant-sensor checks, TPS initialization, blink-code fault diagnosis, instrument-cluster diagnostic mode, charging and starter tests, and circuit-specific fault tracing.
• PVT, EBS, and transmission service: Includes belt inspection, clutch alignment and offset, drive and driven clutch teardown, bushing and one-way-clutch inspection, EBS reassembly, plus Sportsman transmission removal, internal disassembly, assembly, installation, and troubleshooting.
• Six-wheel final drive: Provides front CV and prop-shaft service, U-joint repair, centralized Hilliard front gearcase diagnosis, ADC hydraulic-circuit bleeding, ADC piston replacement, ring-gear backlash setup, and removal and rebuild coverage for the middle and rear gearcases.
• Chassis, brakes, and scheduled service: Covers body and cargo-box removal, A-arm, ball-joint, steering-post, strut, and rear-suspension work; hydraulic brake bleeding, caliper service, disc inspection, and pad burnishing; plus periodic maintenance, lubrication points, alignment, and fluid-service data.

Specifications, Special Tools, and Schematics

The reference data is organized around the work being performed. It includes general and component-specific torque information, tightening patterns, fluid types and capacities, inspection and wear limits, clutch setup data, brake service limits, and electrical voltage, resistance, and current tests. The maintenance section separately identifies the engine, transmission, front ADC gearcase, middle gearcase, rear gearcase, and ADC reservoir rather than treating the 6x6 driveline as a single lubricant circuit.

Special-tool callouts include the PU-43506 fuel-pressure test kit, PU-47082 TPS tester harness, 2871043 flywheel puller, 2870506 clutch puller, 2872292 EBS clutch alignment tool, and PA-48542 ADC gearcase piston installation tool. Polaris EFI Diagnostic Software PU-47063 is described as dealer-only, an important equipment limit for repair planning.

Named visual references include the Oil Flow Chart, EFI System Exploded View, EBS vs. Non-EBS Drive Clutch Exploded Views, ADC Gearcase Exploded View, and Charging System Testing Flow Chart. The final sheets provide the model-specific 2009 Sportsman 800 EFI 6x6 Wire Diagram and a separate ADC Wire Diagram, while circuit-level graphics support AWD, fuel-pump, cooling-fan, and starting diagnosis.

Workshop Cautions and Scope

The fuel chapter states that the EFI system remains pressurized even with the engine stopped, so its pressure-relief and fire-safety precautions apply before fuel-system repair. Two component-specific traps are also documented: changing ECU or harness connections with the ignition on can send a damaging voltage spike through the ECU, while tightening tie-rod jam nuts without holding the rod ends parallel can cause hidden damage and premature wear.

The publication table identifies Owner’s Manual P/N 9922233 and Parts Manual P/N 9922235 as separate references; neither is included in this service-manual PDF. Special tools and the dealer-only Digital Wrench software are likewise referenced, not supplied.