2009 Polaris Sportsman X2 800 EFI Owners Manual

2009 Polaris Sportsman X2 800 EFI Manual

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  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 1
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    2
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    the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-3423764 for assistance.
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    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
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    reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2009 Sportsman 500/800 X2 Owner's Manual P/N 9921845 2
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    TABLE OF CONTENTS Introduction ...4 Safety ...7 Features and Controls ...28 Operation ...50 Emission Control Systems ...74 Maintenance ...75 Adjustments ...126 Troubleshooting ...129 Polaris Products...133 Specifications ...134 Warranty ...138 Maintenance Log ...144 Index ...146 3
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    your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
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    . Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take
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    INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of
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    priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all
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    SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Long Sleeves Eye Protection Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris
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    Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing
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    . Heed all safety warnings outlined in this section of the owner's manual. See the OPERATION section of the owner's manual for proper operating procedures. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how
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    ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. 11
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    SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles
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    Safety Warnings SAFETY Carrying a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. Never allow a passenger to ride in the cargo box. Operating on Pavement
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    could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. Jumps and Stunts Attempting wheelies
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    . Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 62. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
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    . Have a passenger dismount first, then the operator may dismount. • Turn the ATV around and remount, following the procedure described in the owner's manual. See page 64. If the ATV begins rolling backwards: • Keep operator and passenger body weight uphill. • Never apply engine power. • Never apply
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    Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 68. Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back
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    accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area
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    . • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. • Always follow the instructions in the owner's manual for operating with a passenger. See page 58. 19
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    SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather
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    Warnings SAFETY Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe
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    have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label
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    passenger when conditions require • make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERATOR'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. WARNING • Never operate this ATV on HILLS steeper than 15 degrees 15°. To prevent overturn on hilly terrain
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    SAFETY Safety Labels and Locations Passenger Safety Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely Passenger
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    Safety Labels and Locations Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 705 lbs. (320 kg)
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    SAFETY Rack Warning Safety Labels and Locations Box Warning + + Clutch Cover Warning + Rack Warning, Front WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load
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    Safety Labels and Locations SAFETY Reverse Override Warning/AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse. CAUTION Do not push
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    FEATURES AND CONTROLS Switches Headlight Switch Worklight Switch (if equipped) Differential Switch 4X4 Switch Mode/Reverse Override Switch Engine Stop Switch Main Key Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed
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    Switches FEATURES AND CONTROLS Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel
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    controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle
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    in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated
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    FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is
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    Parking Brake FEATURES AND CONTROLS Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake
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    FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary
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    Automatic Transmission Gear Selector FEATURES AND CONTROLS Gear The transmission gear selector is Selector located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the
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    FEATURES AND CONTROLS Fuel Filter (500 EFI) The in-line fuel filter is located under the rubber service cover inside the front box. Have your dealer replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with
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    All Wheel Drive System FEATURES AND CONTROLS The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or 4X4 incline. Always move the 4X4 Switch switch to ADC 4X4
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    FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If
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    Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will
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    FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always return the seat to the 1-up position for single-rider
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    the set-up procedure. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. 8. To return the vehicle to single-rider Locked operation, reverse all steps. Always lower the passenger backrest to the lowest position before folding it
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    FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in
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    Gear 2 P = Park 2. 4X4 Indicator - This 9 indicator illuminates when the 4X4 switch 1 is on either ADC 4X4 or 4X4. 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM too
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 28. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records
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    Instrument Cluster FEATURES AND CONTROLS Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To
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    the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs. Programmable service interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this
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    the button until the hours cycle back to zero. 6. When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed. Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 49 for Blink Codes and Failure Descriptions. Use the following procedure to download blink
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    Instrument Cluster Downloading Codes Blink Code 12 22 22 22 25 31 31 36 36 37 37 41 41 42 42 44 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 63 63 72 73 73 74 74 61 FEATURES AND CONTROLS Rider Information Center Failure Description BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position
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    , accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to
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    Break-In Period OPERATION Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 36. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 80. Add oil if necessary to maintain the level between the safe and add
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    OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Passenger seat lock-out Brake system/lever travel
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    type of tires specified for your vehicle. Always maintain proper tire pressure. 10. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage. 11. Never operate the ATV on a frozen body of water. 12. Do not touch hot
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    OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local
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    Starting the Engine OPERATION 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged
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    OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Wear protective riding gear. See page 8. Perform the pre-ride inspection. See page 52. Place the transmission in PARK. Lock the parking brake. Mount the vehicle from the left side. Sit upright with both feet on the footrests and
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    cargo. 3. Steer in the direction of the turn. 4. Keep both feet on the footrests. 5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest.This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
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    OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driving
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    Driving with a Passenger OPERATION 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 62. 13. A passenger should
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    OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before
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    Driving Uphill OPERATION 15° Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending
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    OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2.
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    Driving Downhill OPERATION 15° Maximum When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Always descend a hill with the transmission in
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    OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 64
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    Turning Around on a Hill (K-Turn) OPERATION 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board,
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    or fast-flowing water. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all
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    Driving Over Obstacles OPERATION Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
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    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid
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    Parking on an Incline OPERATION Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 69
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    OPERATION WARNING Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never carry cargo in the rear box when operating the ATV in the 2-up mode
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    Hauling Cargo OPERATION Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable
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    OPERATION Towing Loads Hauling Cargo Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed
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    Hauling Cargo Dumping Cargo OPERATION 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Dismount the vehicle. 5. Lower the tailgate. WARNING! If cargo weight is
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    Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of
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    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed
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    this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Q Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Steering Front
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    Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar X Air filter, E main element X Brake pad wear Q MAINTENANCE Remarks Miles (Km) 100 (160) 200 (320) 250 (400) 250 (400) 250 (400) 250 (400) 500 (800) 500 (800) 500 (800) 500 (800) 500 (800) 500 (800) 500 (
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    (ADC models) X Fuel filter E Q Spark arrestor Q Toe adjustment 300 H 36 M - Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these
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    Lubrication Guide MAINTENANCE Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Items not listed in the chart
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    MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See page 79. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's
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    Engine Oil MAINTENANCE Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark,
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    MAINTENANCE Engine Oil Oil Level (800 EFI) Access the oil dipstick and fill tube from the left side of the ATV. 1. Position the vehicle on a level surface. 2. Lift the lever lock to remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely, but do not lock it. The
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    Engine Oil MAINTENANCE Oil and Filter Change (500 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. 3. Stop the engine.
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    MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the
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    Engine Oil MAINTENANCE Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank,
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    MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to
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    Engine Oil MAINTENANCE Oil and Filter Change (800 EFI) 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11.
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    MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant.
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    Transmission Oil MAINTENANCE Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. Drain (27-34 Nm). Plug 5. Add 32 oz. (948 ml) of the
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    MAINTENANCE Fluid Level Front Gearcase (Demand Drive) Fluid 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque
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    Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door. 2. View the fluid level in the reservoir. If the level is below the minimum mark, remove the cap and add the recommended fluid. 3. Reinstall the cap securely. Secure the access door and box
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 95
    MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (
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    Cooling System Radiator Coolant MAINTENANCE To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 97
    MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 98
    1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for service. 95
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 99
    assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 100
    . Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original PARK. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 5. Elevate
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 101
    ) Cast Aluminum Steel 27 ft. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Nut Type Lug Nut 2-Piece Flange Nut Nut Torque 90 ft. lbs. (122 Nm) 27 ft. lbs. (37 Nm) 98
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 102
    Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the prefilter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 103
    pointing in either direction. NOTICE: Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service. 100
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    Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door. 2. Remove the suspect fuse from the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 105
    pod cover and disconnect the speedometer harnesses from the speedometer. CAUTION!Hot components can cause burns to skin. Allow lamps to cool before servicing. 5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 6. Turn the lamp counterclockwise to
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 106
    Lights MAINTENANCE High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 107
    MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 108
    Lights MAINTENANCE Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 109
    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 134 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 110
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel. Wet
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 111
    . Reinstall the plug or install a new plug. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 8. If water has been ingested into the PVT, follow the procedure on page
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 112
    of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge
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    PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it
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    PVT System MAINTENANCE The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 115
    There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the repeat the process. 7. Take the vehicle to your dealer for service as soon as possible. 112
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    Battery WARNING MAINTENANCE Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable
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    MAINTENANCE Battery 1. 2. 3. 4. 5. 6. Battery Removal Loosen the battery hold-down bolt. Remove the battery cover. On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 118
    has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 117 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With
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    MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to
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    charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less
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    MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge
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    Cleaning and Storage Washing the Vehicle MAINTENANCE Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 123
    the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always
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    and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
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    . See page 119. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
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    any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine
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    Chart beginning on page 75. Battery Storage See pages 116-117 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover
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    Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always secure the seat in the 1-up position to prevent loss during transporting. 5. Secure the fuel cap and oil cap. 6. Always tie the
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    ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Tip: Accessory springs are available through your Polaris dealer.
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    the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. Be sure the handlebars do
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    ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar.
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    in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range during loading. Use low range or turn around using the K-turn (see page 64). Drive at a higher speed or use
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 133
    TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.8 VDC Check all connections
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 134
    Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range TROUBLESHOOTING Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 135
    TROUBLESHOOTING Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plug(s) Worn or defective spark
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 136
    POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2876144 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 137
    SPECIFICATIONS Sportsman X2 500 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 138
    SPECIFICATIONS Sportsman X2 500 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 139
    SPECIFICATIONS Sportsman X2 800 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 140
    SPECIFICATIONS Sportsman X2 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 141
    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 142
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 143
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 144
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 145
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 146
    U.S.A. EPA Emissions Limited Warranty WARRANTY This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 147
    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 144
  • 2009 Polaris Sportsman X2 800 EFI | Owners Manual - Page 148
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 145
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