Polaris Sportsman 800 6X6 (2009) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 800 6X6 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 800 6X6 (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 6X6 800 EFI SPECIFICATIONS
- Model Number: A09cl76aa
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
- Polaris Lubricants, Maintenance And Service Products
- Polaris Lubricant Symbol Identification
- Pre-Ride / Daily Inspection
- Lubrication / Grease Points
- Front Gearcase Lubrication
- Middle Gearcase Lubrication
- Rear Gearcase Lubrication
- 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 Inspection
- 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
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
- Front Storage Removal
- Front Storage Installation
- Front Fender Removal/Installation
- Rear Fender Panel Removal / Installation
- Radiator Screen Removal
- Body Assembly Exploded View
- Bumper / Storage / Rack 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
- Front Strut Assembly
- Rear Torsion Bar Assembly
- Rear / Middle Suspension Exploded View
CARGO BOX
- Exploded View
- 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
MIDDLE GEARCASE
- Removal
- Disassembly And Inspection
- Reassembly
- Installation
- Middle Gearcase Exploded View
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
SPECIFICATIONS
- Torque Specifications
- Lubricant / Capacity
TRANSMISSION SERVICE
- Transmission Removal
- Disassembly
- Assembly
- Transmission Installation
- Troubleshooting
SPECIFICATIONS
- Torque Table
- Component Service Limits
BRAKE SYSTEM EXPLODED VIEW
- System Components
BRAKE CALIPER EXPLODED VIEWS
- Front Caliper Assembly
- Rear Caliper Assembly
HYDRAULIC BRAKE SYSTEM
- Operation Overview
- Brake Noise Troubleshooting
- Brake Bleeding / Fluid Change
MASTER CYLINDER
- Removal
- Installation
FRONT BRAKE PADS
- Removal And Inspection
- Assembly
- Brake Burnishing Procedure
FRONT BRAKE DISC
- Inspection
- Removal / Replacement
FRONT CALIPER
- Removal And Disassembly
- Inspection
- Reassembly
- Installation
REAR BRAKE PADS
- Removal
- Installation
- Brake Burnishing Procedure
REAR CALIPER
- Removal And Inspection
- Assembly
REAR BRAKE DISC
- Inspection
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 - 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
- Brake Lamp/Tail Lamp Replacement
- Brake Light Switch
FUEL SENDER
- Testing
ACCESSORY POWER
- Wire Connections
STARTER SYSTEM
- Sportsman 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. Note: Make Sure Engine Crankshaft Is Free To Turn Before Proceeding With Dynamic Testing Of Starter System. A Digital Multitester Must Be Used For This Test
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