Polaris Sportsman 6X6 800 EFI Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Sportsman 6X6 800 EFI 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 6X6 800 EFI
MODEL NUMBER: A09CL76AA
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_08-SPORTSMAN TRANSMISSION
CH_09-BRAKES
CH_10-ELECTRICAL
WIRE DIAGRAMS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9922030
Total Pages : 322

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.

9922030_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 6×6 800 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
9922030_CH_02-MAINTENANCE
TABLE OF CONTENTS
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
9922030_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
9922030_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
9922030_CH_05-BODY / STEERING / SUSPENSION
GENERAL INFORMATION 5.2
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
9922030_CH_06-CLUTCH SYSTEM
SPECIAL TOOLS AND SPECIFICATIONS 6.2
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
9922030_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
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
9922030_CH_08-SPORTSMAN TRANSMISSION
TABLE OF CONTENTS
TRANSMISSION EXPLODED VIEW
Sportsman Transmission
SPECIFICATIONS
Torque Specifications
Lubricant / Capacity
TRANSMISSION SERVICE
Transmission Removal
Disassembly
Assembly
Transmission Installation
Troubleshooting
9922030_CH_09-BRAKES
TABLE OF CONTENTS
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
9922030_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 – 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
9922030_WIRE DIAGRAMS

 

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Polaris Sportsman 6X6 800 EFI Repair Service Manual 2009.pdf

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