Polaris Sportsman X2 700 /800 EFI /800 Touring Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Sportsman X2 700 /800 EFI /800 Touring has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

2009 SPORTSMAN 800 EFI
MODEL NUMBER: A09MN76AX, AZ
ENGINE MODEL: EH076OLE

2009 SPORTSMAN X2 800 EFI
MODEL NUMBER: A09TN76AL, AX, AZ
ENGINE MODEL: EH076OLE

2009 SPORTSMAN TOURING 800 EFI
MODEL NUMBER: A09DN76AB, AL / A09DN76FC
(Domestic) (International)
ENGINE MODEL: EH076OLE


TABLE OF CONTENTS :

CH_01-GENERAL INFORMATION
CH_02-MAINTENANCE
CH_03-ENGINE
CH_04-FUEL INJECTION
CH_05-BODY / STEERING / SUSPENSION
CH_06-CLUTCH SYSTEM
CH_07-FINAL DRIVE
CH_08r01-TRANSMISSION
CH_09-BRAKES
CH_10-ELECTRICAL
CH_11-800 TOURING EFI INTERNATIONAL
WIRE DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921795
Total Pages : 386


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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9921795_CH_01-GENERAL INFORMATION
    TABLE OF 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
            
9921795_CH_02-MAINTENANCE
    TABLE OF CONTENTS
        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
            
9921795_CH_03-ENGINE
    TABLE OF CONTENTS
        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
            
9921795_CH_04-FUEL INJECTION
    TABLE OF CONTENTS
        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
            
9921795_CH_05-BODY / STEERING / SUSPENSION
    TABLE OF CONTENTS
        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
            
9921795_CH_06-CLUTCH SYSTEM
    TABLE OF CONTENTS
        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
            
9921795_CH_07-FINAL DRIVE
    TABLE OF CONTENTS
        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
            
9921795_CH_08r01-TRANSMISSION
    TABLE OF CONTENTS
    SPORTSMAN TRANSMISSION
        TRANSMISSION EXPLODED VIEW
            Sportsman Transmission 
        SPECIFICIATONS
            Torque Specifications
            Lubricant / Capacity
        TRANSMISSION SERVICE
            Transmission Removal
            Disassembly
            Assembly
            Transmission Installation
            Troubleshooting
    X2 / TOURING TRANSMISSION
        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
            
9921795_CH_09-BRAKES
    TABLE OF CONTENTS
        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
            
9921795_CH_10-ELECTRICAL
    TABLE OF CONTENTS
        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. 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
            
9921795_CH_11-800 TOURING EFI INTERNATIONAL
    TABLE OF CONTENTS
        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
            
9921795_WIRE DIAGRAMS
    2009 WIRE DIAGRAMS
        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
        
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