Vehicle Segment:
Heavy-duty All-Terrain (ATV) / Utility Vehicle
Key Selling Points Vehicle:
The Polaris Sportsman 6x6 800 EFI is a robust and versatile six-wheel-drive vehicle designed for demanding tasks, utility work, and challenging off-road conditions. Its extended wheelbase and 6x6 drivetrain provide superior traction and load-carrying capacity.
Competitors:
Typically competes with other manufacturers' large-chassis, multi-purpose ATVs and utility vehicles from brands like Can-Am (Outlander 6x6 series), John Deere, and Arctic Cat.
Manual Value Proposition:
This official factory service manual is an indispensable resource for owners and technicians seeking to maintain, diagnose, and repair the Polaris Sportsman 6x6 800 EFI. Its factory origin ensures accuracy, completeness, and the correct procedures for all aspects of the vehicle.
Engine Mechanical:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, rods, crankshaft, camshaft, valve train, etc.). Covers cylinder head, block, oil pump, oil pan, and associated seals and gaskets.
Engine Fuel System:
Detailed procedures for fuel pump, fuel filter, fuel injectors, and fuel lines. Includes carburetor (if applicable, though EFI is specified, some basic intake troubleshooting might be covered) and intake manifold service.
Engine Ignition System:
Covers spark plugs, spark plug wires, ignition coils, and ignition timing adjustments. Includes sensor diagnostics related to ignition.
Cooling System:
Radiator, radiator fan, oil radiator (oil cooling), coolant hoses, fan shroud, and thermostat service. Includes coolant flush and replacement procedures.
Exhaust System:
Muffler, downpipe, catalytic converter (if applicable), exhaust gaskets, and headers replacement and repair.
Transmission Drivetrain:
Covers transmission fluid changes, internal transmission components (if applicable to this model), transfer case service, and axle shaft maintenance. Includes shift linkage and shifter cable adjustments.
Braking System:
Front and rear brake pad replacement, brake shoe replacement, rotor replacement, brake fluid flush, brake line service, and hydraulic system bleeding. Covers brake system troubleshooting.
Suspension Steering:
Detailed procedures for shocks, struts, suspension components, and steering system maintenance and repair. Includes wheel alignment and tire rotation.
Electrical System:
Wiring harness diagnostics, sensor testing and replacement (oil sensor, pressure sensor, etc.), lighting system troubleshooting, battery replacement, and starter/alternator service. Includes comprehensive wiring diagrams.
Body Chassis:
Covers body panels, doors, hood, bumpers, grilles, trim, and associated fasteners and seals. Includes interior components like dashboard, center console, and door panels.
Routine Maintenance:
Oil change, transmission fluid change, fluid level checks, filter replacements (air, fuel), spark plug replacement, and battery maintenance.
Troubleshooting Diagnostics:
Comprehensive diagnostic procedures for all major systems, including error code interpretation (if applicable), symptom-based troubleshooting, and component testing.
Engine Repair:
Detailed step-by-step instructions for engine disassembly, repair, and reassembly, including critical torque specifications and clearances.
Transmission Repair:
Procedures for transmission servicing, internal component inspection, and repair as required for this model.
Brake Repair:
Complete brake system service, including caliper, master cylinder, and line replacement, as well as pad and rotor service.
Electrical Repair:
Wiring harness repair, component testing and replacement, and troubleshooting of electrical faults using provided diagrams.
Suspension Steering Repair:
Service and replacement procedures for all suspension and steering components, including wheel bearings and hub assemblies.
Bodywork Cosmetics:
Procedures for panel removal, installation, and basic cosmetic repairs. Includes interior trim and component replacement.
Special Tools Procedures:
Identification and usage of specialized tools required for various repair and maintenance tasks.
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance and basic adjustments to complete engine and transmission rebuilds, electrical diagnostics, and chassis work. Factory-level detail.
Engine Type:
4-stroke, 4-valve, SOHC, Liquid-Cooled V-Twin
Bore X Stroke:
Not specified in provided info, but typical for this engine family
Fuel Delivery:
Electronic Fuel Injection (EFI)
Horsepower:
Approximately 50-55 HP (estimated for model year)
Torque:
Not specified in provided info
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
6.35 gal (24 L) (typical for model)
Oil Type:
SAE 5W-50 Synthetic (typically Polaris branded)
Oil Capacity:
3.1 US qt (2.9 L) (typical, with filter change)
Cooling Medium:
Liquid-Cooled
Engine Oil Change:
Every 100 hours or annually (whichever comes first)
Spark Plug Inspection Replacement:
Every 100 hours or annually
Air Filter Cleaning Replacement:
Inspect every 50 hours, clean as needed, replace annually or more frequently in dusty conditions.
Transmission Fluid Change:
Every 200 hours or annually
Brake Fluid Flush:
Every 2 years
Engine Oil Specification:
SAE 5W-50 Synthetic
Gearcase Lubricant Specification:
Polaris AGL Synthetic Gearcase Lubricant
Coolant Specification:
Ethylene Glycol based antifreeze/coolant (50/50 mix with distilled water)
Common Wear Items:
Drive belts (PVT), suspension bushings, ball joints, wheel bearings, and brake pads due to heavy use and terrain.
Efi System Maintenance:
Regular cleaning of fuel injectors and throttle body can prevent performance issues. The manual will detail diagnostic procedures for EFI sensors.
