Polaris Sportsman 800 (2009) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 800 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 800 (2009).

 
CONTENTS:

MODEL INFORMATION
- Model Number
- Engine Designation Numbers
- Vin Identification
- Transmission I.D. Location
- Engine And Machine Serial Numbers
- Publications
- Paint Codes
- Replacement Keys
2009 SPORTSMAN 800 EFI
- Model Number: A09mn76ax, Az
2009 SPORTSMAN X2 800 EFI
- Model Number: A09tn76al, Ax, Az
2009 SPORTSMAN TOURING 800 EFI
- Model Number: A09dn76ab, Al / A09dn76fc
MISC. NUMBERS/CHARTS
- Standard Torque Specifications
- Special Tools
- Sae Tap Drill Sizes
- Metric Tap Drill Sizes
- Decimal Equivalents
- Conversion Table
- Glossary Of Terms
MAINTENANCE
- Overview
- Periodic Maintenance Chart
LUBRICATION / FLUIDS
- Sportsman Component Locations
- Sportsman X2-Touring Component Locations
- Polaris Lubricants, Maintenance And Service Products
- Polaris Lubricant Symbol Identification
- Pre-Ride / Daily Inspection
- Lubrication / Grease Points
- Front Gearcase Lubrication
- Rear Gearcase Lubrication - 800 Efi
- Transmission Lubrication
- Adc Differential Hydraulic Circuit Fluid Change
VEHICLE INSPECTION
- Shift Link Rod Inspection
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (Etc Switch) Adjustment
- Fuel System
- Vent Lines
- Compression Test
- Engine Mounts
- Spark Plug
- Active Descent Control (Adc) Reservoir Level
- Battery Maintenance
- Cooling System
- Coolant Strength / Type
- Cooling Hoses
- Radiator
- Cooling System Pressure Test
- Reservoir Level Inspection
- Radiator Coolant Level
- Air Filter Service
- Air Box Sediment Tube
- Engine Breather Hose
- Pvt Inspection / Drying Procedure
- Engine Ground
- Engine Oil Level
- Oil/Filter Change
- Steering Inspection
- Tie Rod / Steering
- Camber/Caster
- Wheel Alignment
- Toe Alignment
- Exhaust Pipe
- Brake System Inspection
- Brake Pads
- Brake Hose Inspection
- Auxiliary (Rear) Brake Test
- Auxiliary Brake Adjustment
- Suspension: Spring Preload Adjustment
- Front Suspension
- Rear Suspension
- Cv Shaft Boot Inspection
- Atv Controls
- Wheel Inspection
- Wheel Removal: Front Or Rear
- Wheel Installation
- Tire Pressure
- Tire Inspection
- Frame, Nuts, Bolts, Fasteners
- Front / Rear Storage Compartments
- Winch Operation (If Equipped)
- Cleaning And Storage Of Atv
- Maintenance Schedule
- Maintenance Schedule
SPECIFICATIONS
- Crankcase Exploded Views
- Engine Fastener Torque Patterns
- Torque Specifications
- 800 Efi Engine Service Specifications
- Special Tools
GENERAL ENGINE SERVICE
- Accessible Components
- Piston Identification
- Cooling System Specifications
- Cooling System Pressure Test
- Four Stroke - Coolant Air Bleeding Procedure
- Engine Removal (Typical)
- Engine Installation Notes
- Cylinder Hone Selection And Honing Procedure
- Honing To Deglaze
- Cleaning The Cylinder After Honing
- Oil Flow Chart
- Engine Lubrication Specifications
- Oil Pressure Test
ENGINE DISASSEMBLY AND INSPECTION
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Push Rods
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp
- Valve Seal/Spring Service (On Engine)
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Reassembly
- Valve Sealing Test
- Cylinder Removal
- Valve Lifter Removal/Inspection
- Piston Removal
- Cylinder Inspection
- Piston-To-Cylinder Clearance
- Piston/Rod Inspection
- Piston Ring Installed Gap
- Starter Drive/Bendix Removal Inspection
- Flywheel / Stator Removal / Inspection
- Engine Crankcase Disassembly / Inspection
- Camshaft Inspection
ENGINE REASSEMBLY
- Crankcase Reassembly
- Flywheel / Stator Installation
- Cylinder Head Reassembly
TROUBLESHOOTING
- Engine
- Cooling System
800 EFI EXHAUST SYSTEM
- Dual Exhaust Layout
GENERAL INFORMATION
- Special Tools
- Service Notes
- Efi System Exploded View
- Efi System Component Locations
- Fuel Tank Assembly
- Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION
- Principal Components
- Efi Operation Overview
- Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
- Operation Overview
- Ecu Service
- Ecu Replacement
FUEL PUMP
- Operation Overview
- Fuel Pump Test
- Fuel Pump / Tank Assembly Replacement
FUEL PRESSURE REGULATOR
- Operation Overview
- Fuel Pressure Regulator Test
- Fuel Pressure Regulator Replacement
FUEL FILTER
- General Information
- Fuel Filter Service
- Fuel Filter Replacement
FUEL INJECTORS
- Operation Overview
- Fuel Injector Service
- Fuel Injector Replacement
CRANKSHAFT POSITION SENSOR (CPS)
- Operation Overview
- Crankshaft Position Sensor Test
- Crankshaft Position Sensor (Cps) Replacement
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
- Operation Overview
- Temperature And Barometric Air Pressure Sensor Test
- Temperature And Barometric Air Pressure Sensor Replacement
THROTTLE POSITION SENSOR (TPS)
- Operation Overview
- Throttle Position Sensor Test
- Throttle Position Sensor Replacement
- Throttle Position Sensor Adjustment
ENGINE TEMPERATURE SENSOR
- Operation Overview
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
TROUBLESHOOTING
- Diagnostics Using “Blink Codes”
- Efi Troubleshooting
- Efi Circuit - Power On
- Efi Circuit - Crank Position Sensor
- Efi Circuit - Fuel Pump
- Efi Circuit - Throttle Position Sensor
- Efi Circuit - Temperature - Barometric Air Pressure Sensor
- Efi Circuit - Engine Temperature
- Efi Circuit - Malfunction Indicator Light
GENERAL INFORMATION
- Torque Specifications
- Special Tools
- Decal Replacement
- Plastic Insert Removal / Installation
BODY
- Side Panel Removal
- Front Cover Removal / Installation
- Foot Well Removal / Installation
- X2-Touring Foot Well Removal / Installation
- Front Storage Removal
- Front Storage Installation
- Sportsman Rear Rack Removal / Installation
- Front Cab/Fender Removal/Installation
- Sportsman Rear Cab / Fender Removal / Installation
- X2 Rear Quarter Panel Removal / Installation
- Sportsman Rear Storage Removal / Installation
- Radiator Screen Removal
- Sportsman Body Assembly Exploded View
- X2- Touring Body Assembly Exploded View
- Touring Body/Rack Assembly Exploded View
- Body / Rack Exploded Views
- Touring Body/Seat Assembly Exploded View
- Headlight Pod Exploded View
STEERING
- Handlebar Block Installation Procedure
- Steering / A-Arm Exploded View
- A-Arm Replacement
- Ball Joint Replacement
- Steering Post Removal
- Steering Post Assembly
SUSPENSION
- Front Strut Cartridge Replacement
- Strut Assembly
- Sportsman Rear Suspension Assembly
- X2- Touring Rear Suspension Exploded View
- X2 Torsion Bar Exploded View
X2 CARGO BOX
- Exploded View
- Removal / Installation
X2 SEAT ASSEMBLY
- Exploded Views
- X2 Seat Operation - Configuring Cargo Box For Passenger Riding
- X2 Driver Seat Backrest Removal / Installation
- X2 Passenger Seat Backrest Removal / Installation
SPECIAL TOOLS AND SPECIFICATIONS
- Special Tools
- Component Fastener Torques
PVT EXPLODED VIEWS
- Pvt Sealing And Ducting Components
- Drive Clutch Exploded Views (Ebs Vs. Non-Ebs)
- Driven Clutch Exploded Views
- Engine Braking System (Ebs) Exploded View
PVT SYSTEM
- Pvt Operation Overview
- Drive Clutch Operation
- Driven Clutch Operation
- Ebs Clutch Operation
- Pvt Maintenance / Inspection
- Drive Clutch Spring
- Optional Shift Weights
- Pvt Drying
- Pvt Disassembly
- Pvt Installation
- Drive Belt Removal / Inspection
- Drive Belt Installation
- Clutch Alignment
- Clutch Offset
EBS DRIVE CLUTCH SERVICE
- Drive Clutch Disassembly
- Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- Drive Clutch Bushing Service
- One-Way Clutch Inspection (Drive Clutch)
- Drive Clutch Reassembly
EBS DRIVEN CLUTCH SERVICE
- Driven Clutch Disassembly
- Driven Clutch Bushing Removal/ Installation
- Ebs Driven Clutch Reassembly
PVT TROUBLESHOOTING
- Overheating
- Problem, Cause And Remedy Chart
SPECIFICATIONS
- Torque Table
- Special Tools
- Gearcase Fluid / Capacity
FRONT HUB
- Disassembly
- Assembly
FRONT DRIVE SHAFT (CV) SERVICE
- Removal
- Installation
- Inspection
- Cv Joint/Boot Replacement
PROP SHAFT - FRONT OR REAR
- Removal And Installation
U-JOINT
- Disassembly
- Assembly
DRIVE AXLE EXPLODED VIEWS
- Drive Shafts And Propshafts
FRONT GEARCASE - CENTRALIZED HILLIARD W/ ACTIVE DESCENT CONTROL
- Operation
- Adc Gearcase Exploded View
- Adc Operation
- Front Gearcase Diagnosis
- Gearcase Removal
- Gearcase Installation
- Coil Testing
- Adc Differential Hydraulic Circuit Bleeding
- Disassembly / Inspection
- Adc Gearcase Piston Replacement Procedure
- Assembly
- Setting Ring Gear Backlash
REAR HUB
- Removal
- Disassembly
- Assembly
- Installation
REAR DRIVE (CV) SHAFT
- Removal
- Service
- Cv Boot Replacement
- Installation
- Drive Shaft And Cv Joint Handling Tips
REAR GEARCASE
- Removal
- Disassembly And Inspection
- Reassembly
- Installation
- Rear Gearcase Exploded View
TRANSMISSION EXPLODED VIEW
- Sportsman Transmission
SPECIFICIATONS
- Torque Specifications
- Lubricant / Capacity
TRANSMISSION SERVICE
- Transmission Removal
- Disassembly
- Assembly
- Transmission Installation
- Troubleshooting
TRANSMISSION EXPLODED VIEWS
- Transmission Exploded View
- Mounting Exploded View
SPECIFICATIONS
- Torque Specifications
- Special Tools
- Lubrication
TRANSMISSION SERVICE
- Gear Selector Removal
- Transmission Removal
- Transmission Installation
- Troubleshooting Checklist
- Transmission Disassembly
- Transmission Assembly
- Transmission Front Output Shaft Backlash Procedure
SPECIFICATIONS
- Torque Table
- Component Service Limits
BRAKE SYSTEM EXPLODED VIEWS
- X2, Touring System Component Exploded View
- Sportsman System Component Exploded View
BRAKE CALIPER EXPLODED VIEWS
- Sportsman And X2, Touring Front Caliper Assembly
- X2, Touring Rear Caliper Assembly
- Sportsman Rear Caliper Assembly
HYDRAULIC BRAKE SYSTEM
- Operation Overview
- Brake Noise Troubleshooting
- Brake Bleeding / Fluid Change
FRONT MASTER CYLINDER
- Removal
- Installation
FRONT BRAKES
- Pad Removal
- Assembly
- Brake Burnishing Procedure
FRONT BRAKE DISC
- Inspection
- Removal / Replacement
FRONT CALIPER
- Removal
- Inspection
- Reassembly
- Installation
REAR BRAKE PAD
- X2, Touring Pad Removal
- X2, Touring Pad Installation
- Sportsman Rear Pad Removal
- Sportsman Rear Pad Installation
- Brake Burnishing Procedure
X2, TOURING REAR CALIPER
- Removal
- Inspection
- Reassembly
SPORTSMAN REAR CALIPER
- Removal And Inspection
- Assembly
REAR BRAKE DISC
- Inspection
REAR MASTER CYLINDER
- X2, Touring Exploded View
- Overview
- X2, Touring Rear Master Cylinder Removal And Installation
- Sportsman Rear Master Cylinder Removal / Installation
- Pedal Removal And Installation
TROUBLESHOOTING
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
INSTRUMENT CLUSTER
- Overview
- Instrument Cluster Diagnostic Mode
- Setting A New Service Interval
- Efi Diagnostic Mode
- Speedometer Removal
- Speedometer Installation
SPEEDOMETER TROUBLESHOOTING
- Test 1 - No All Wheel Drive
- Test 2 - No Display / Test 3 - No Reverse Speed Limit
- Test 4 - No Awd Hub Safety Limiter
- Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
- Test 7 - No Fuel Gauge / Test 8 - Transmission Switch
ACTIVE DESCENT CONTROL (ADC) COIL
- Operation Overview
- Diagnosing System Failures
ALL WHEEL DRIVE (AWD) COIL
- Operation Overview
- Diagnosing System Failures
COOLING SYSTEM COMPONENTS
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor
- Fan Motor Current Draw
GEAR POSITION INDICATOR SWITCH
- Test Diagram
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- Etc Switch Operation
- Etc Operation Test
IGNITION SYSTEM
- Flywheel Identification
- Efi - Dc/Cdi Ignition Overview
- Alternator/Ignition Components - 700/800 Efi
- Crankshaft Position Sensor Gap
- Ignition System Troubleshooting
CHARGING SYSTEM
- Current Draw - Key Off
- Charging System “Break Even” Test
- Alternator Output Test
- Charging System Testing Flow Chart
RELAYS
- Operation
FUSES/CIRCUIT BREAKER
- Operation
LIGHTING
- High Beam Headlight Bulb Replacement
- Headlight Housing Replacement
- High Beam Headlight Adjustment
- Lower Headlamp Removal / Installation
- Low Beam Headlight Adjustment
- Headlamp Switch Test
- Work Light / Differential Switch
- Sportsman / Touring Brake Light / Work Light Replacement
- X2 Brake Light / Work Light Replacement
- Brake Light Switch
FUEL SENDER
- Testing
X2 / TOURING DIFFERENTIAL SYSTEM
- Solenoid Testing
- Solenoid Replacement
- Differential Relay Operation
- Differential Relay Testing
X2 / TOURING SPEED SENSOR
- Testing
- Replacement
ACCESSORY POWER
- Wire Connections
STARTER SYSTEM
- Sportsman Starter Lockout Overview And Diagnostic
- X2 /Touring Starter Lockout Overview And Diagnostic
- Troubleshooting
- Voltage Drop Test
- Starter Motor Removal / Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly / Installation
- Starter Solenoid Bench Test
- Starter Drive
- Starter Exploded View
STARTER SYSTEM TESTING FLOW CHART
- Condition: Starter Fails To Turn Motor.
BASIC WINCH WIRING- PRE-WIRED MODELS
BATTERY
- Battery Identification
- Battery Activation (Conventional)
- Battery Terminals/Bolts
- Conventional Battery Inspection / Removal
- Conventional Battery Installation
- Conventional Battery Testing
- Conventional Battery Ocv - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Battery Load Test
- Off Season Storage
- Charging Procedure
- Low Maintenance Battery
- Low Maintenance Battery Charging
- Low Maintenance Battery Inspection / Removal
- Low Maintenance Battery Installation
- Low Maintenance Battery - Ocv- Open Circuit Voltage Test
- Low Maintenance Battery Load Test
- Low Maintenance Battery Off-Season Storage
- Low Maintenance Battery Charging Procedure
TROUBLESHOOTING DIAGRAMS
- Overview
- All Wheel Drive - Efi
- Charging Circuit - Efi
- Cooling Fan - Efi
- Fuel Pump - Efi
- Gear Switch - Efi
- Power Circuit - Efi
- Reverse Override - Efi
- Fan Control - Efi
- Start Circuit - Efi
- Start Enable - Efi
800 TOURING EFI INTERNATIONAL BRAKE SYSTEM
- Overview
- Exploded View
800 TOURING EFI INTERNATIONAL STEERING POST AND LOCK ASSY
- Steering Assembly Exploded View
800 TOURING EFI INTERNATIONAL ELECTRICAL
- Turn / Hazard Signal Diagram
2009 SPORTSMAN 800 EFI WIRE DIAGRAM
2009 SPORTSMAN 800 X2 / 800 TOURING EFI WIRE DIAGRAM
2009 SPORTSMAN 800 TOURING EFI INTERNATIONAL WIRE DIAGRAM
SPORTSMAN ACTIVE DESCENT CONTROL (ADC) WIRE DIAGRAM
SPORTSMAN 800 EFI CIRCUIT BREAKOUT
SPORTSMAN 800 EFI CIRCUIT BREAKOUT
SPORTSMAN 800 EFI CIRCUIT BREAKOUT