The Polaris Sportsman 800 EFI HO 6x6 is a robust utility all-terrain vehicle designed for demanding tasks and adventurous excursions. Produced between 2005 and 2012, this model is distinguished by its powerful 800cc V-twin engine featuring Electronic Fuel Injection (EFI) for optimal performance and reliability. Its signature 6x6 all-wheel-drive system, coupled with a long wheelbase, provides exceptional traction and stability across varied terrains, making it ideal for work, hunting, and recreational activities. With integrated racks, substantial towing capacity, and ergonomic design, the Sportsman 800 EFI HO 6x6 exemplifies a commitment to engineering quality and user capability in the powersports market.
This comprehensive workshop service repair manual provides detailed guidance for the maintenance and repair of the Polaris Sportsman 800 EFI HO 6x6 models from 2005 to 2012. It covers all essential aspects, including powertrain systems, chassis components, and electrical systems, offering in-depth procedures for engine, transmission, suspension, and braking systems. The manual details scheduled maintenance, diagnostic troubleshooting, and step-by-step repair instructions, ensuring owners, mechanics, and technicians have the necessary information to keep the vehicle in optimal condition. Its extensive scope, presented in English, facilitates everything from routine servicing to complex overhauls, supported by clear illustrations and technical specifications.
Model:
Sportsman 800 EFI HO
Model Years Covered By Manual:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Engine Code Indicator:
EFI HO
Segment:
Heavy-Duty All-Terrain (ATV) Utility Vehicle
Key Competitors:
Honda Foreman, Yamaha Kodiak, Can-Am Outlander (during its respective model years)
Design:
6x6 All-Wheel Drive system for superior traction and load-carrying capacity, Long wheelbase for stability
Engine:
Powerful 800cc V-Twin engine with Electronic Fuel Injection (EFI) for enhanced performance and reliability
Utility:
Integrated racks, towing capabilities, suitable for work, hunting, and recreation
Primary Coverage:
Service, Repair, Workshop
Estimated Page Count:
Extensive (typical for full workshop manuals, often 500+ pages, exact count not specified but implies comprehensive)
Type:
Workshop Service Repair Manual
Powertrain:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Drivetrain (including 6x6 AWD system)
Chassis:
Suspension (Front and Rear), Steering, Brakes, Wheels and Tires, Frame and Bodywork
Electrical:
Wiring Diagrams, Lighting, Ignition, Starting System, Charging System, EFI Control System, Accessories
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Lubrication, Tire Pressure Checks
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs)
Repair:
Component Removal and Installation, Overhaul Procedures, Adjustment Procedures, Reassembly Steps
Depth:
Comprehensive (covering routine maintenance to complete engine and transmission rebuilds, including electronic diagnostics)
File Type:
PDF (Portable Document Format)
Clarity:
High Resolution (indicated by 'illustrated with clear step-by-step instruc...')
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Engine Type:
Four-Stroke, V-Twin, SOHC
Displacement:
760cc (approx.)
Bore X Stroke:
Not specified in product info, but typically around 90mm x 70mm for this engine family.
Horsepower:
Estimated 50-55 HP (typical for the 800cc V-Twin of this era)
Torque:
Not specified in product info, but known for strong low-end torque.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Electronic CDI with Digitalis Ignition Control
Cooling System:
Liquid-Cooled
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive Modes:
2WD/AWD On-Demand (selectable, plus the inherent 6x6 drive)
Length:
Approx. 103 in. (varies slightly by year)
Width:
Approx. 46 in. (varies slightly by year)
Height:
Approx. 50 in. (varies slightly by year)
Front Rack Capacity:
100 lbs (45.4 kg)
Rear Rack Capacity:
200 lbs (90.7 kg)
Dry Weight:
Approx. 675-700 lbs (306-318 kg) - varies by year and configuration
Towing Capacity:
1500 lbs (680.4 kg)
Payload Capacity:
Not specified, but typically 400-500 lbs for the rider and cargo.
Rollover Protection:
N/A (ATVs do not have standardized crash ratings like cars. Operator awareness and safety gear are paramount.)
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Engine Braking:
Integrated engine braking via PVT system
Lighting:
Dual Halogen Headlights, Tail Light, Brake Light
Ergonomics:
Ergonomic seating position, hand grips, footwells for rider comfort and control.
Dashboard:
Digital/Analog instrument cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, and warning lights.
Traction Control:
Electronic 6x6 AWD system for enhanced traction in challenging terrain.
Accessories:
Provision for accessory electrical connections (winch, lights, etc.)
Oil Change:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact intervals).
Air Filter Cleaning:
Every 25 hours or as needed in dusty conditions.
Spark Plug Replacement:
Refer to manual, typically around 100-200 hours or annually.
Engine Oil Type:
Polaris PS-4 5W-50 Full Synthetic (or equivalent API SG rated oil with JASO MA certification)
Engine Oil Capacity:
Approximately 2.1 US quarts (2.0 liters) with filter change. (Verify in manual)
Coolant Type:
Ethylene Glycol based antifreeze/coolant with corrosion inhibitors. (e.g., Polaris Blue Premium Antifreeze)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Gear Lube Type:
Polaris Gearcase Lubricant (or SAE 80W-90 GL-5 gear oil for differentials and transaxle. Verify in manual.)
Common Wear Items:
Drive belts (PVT), tie rod ends, ball joints, wheel bearings, brake pads due to heavy use and terrain.
Electrical Concerns:
Occasional issues with stator, voltage regulator, or EFI sensors, particularly with age and exposure to elements.
Cooling System:
Potential for radiator leaks or fan issues if not properly maintained.
Manufacturer:
Polaris Industries, known for its pioneering role in the powersports industry, particularly with snowmobiles and ATVs.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, emphasizing comfort, capability, and innovation. The 800 EFI HO was a significant model within this line.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Production Period For This Manual:
Covers models from 2005 through 2012, indicating a substantial production run.
Industry Acclaim:
Polaris Sportsman models have consistently received positive reviews and awards within the powersports industry for their performance, comfort, and utility over the years.
