Positioning:
The Polaris Sportsman 6x6 800 EFI was positioned as a premium, heavy-duty utility ATV, offering exceptional traction and hauling capability for demanding tasks in agriculture, hunting, and off-road exploration.
Competitors:
Competed with other large-displacement 6x6 ATVs from manufacturers like Arctic Cat (Prowler XT) and John Deere, as well as high-end 4x4 models from brands like Can-Am (Outlander) and Yamaha (Grizzly).
Features:
Key features included its powerful 800cc ProStar engine, advanced EFI system for optimal performance and fuel efficiency, true 6-wheel drive with locking differentials for superior traction, independent suspension on all wheels, and a substantial towing and payload capacity.
Coverage Scope:
Comprehensive dealership-level repair and maintenance for the 2009 Polaris Sportsman 6X6 800 EFI.
Estimated Page Count:
Approximately 500-700 pages (typical for factory service manuals of this era and complexity).
Type:
Factory Service Manual / Repair Manual
Format:
Reprint (likely print-on-demand or a high-quality reproduction of the original dealership manual).
Engine:
Detailed diagnostics, overhaul procedures, component testing, timing, cooling system, lubrication, fuel injection (EFI) system.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, clutch service, belt inspection and replacement, driveshaft, differential, and 6x6 drive system servicing.
Electrical System:
Complete wiring diagrams, battery system, charging system (stator, regulator/rectifier), starting system, lighting, ignition system, EFI control module (ECU) diagnostics.
Suspension Steering:
Front and rear suspension component inspection and replacement, shock absorber adjustments, steering linkage, tie rods, wheel bearing service.
Braking System:
Hydraulic brake system diagnostics, caliper service, brake line replacement, master cylinder service, parking brake adjustment.
Fuel System:
Fuel pump testing, fuel filter replacement, fuel injector diagnostics, throttle body cleaning and adjustment.
Bodywork Chassis:
Frame inspection, body panel removal and installation, seat, racks, and accessory mounting.
Cooling System:
Radiator, coolant hoses, thermostat, fan operation, coolant flush and refill procedures.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, spark plug replacement, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts for common symptoms (e.g., starting issues, engine performance problems, electrical faults).
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Diagnostics:
In-depth diagnostic procedures for EFI system, ignition system, and mechanical components.
Depth:
Dealership-level technical information, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission overhauls.
Digital Format Details:
If digital, typically a searchable PDF. High-resolution scans ensuring clarity of text and illustrations.
Print Quality:
High-quality reprint, designed for durability in a workshop environment. Clear text and sharp, detailed illustrations.
Binding:
Likely professionally bound with a durable cover for workshop use (e.g., spiral bound, perfect bound, or section sewn).
Paper Type:
Heavy-duty paper stock, resistant to grease and wear, suitable for workshop conditions.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, V-twin, Polaris ProStar engine.
Displacement:
760cc (approximate, actual may vary slightly based on specific engine code).
Horsepower:
Approximately 55-60 HP (typical for this engine configuration).
Torque:
Approximately 52-55 lb-ft (typical for this engine configuration).
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Ignition System:
Electronic Ignition (CDI).
Cooling Method:
Liquid-cooled with forced circulation.
Oil Type Capacity:
SAE 5W-50 Synthetic ATV Oil recommended. Capacity typically around 2.0-2.5 quarts (1.9-2.4 liters) including filter. Specific part number for filter: Polaris 2204745 (check manual for exact superseded part).
Type:
Automatic Polaris Variable Transmission (PVT) with engine braking.
Gear Selection:
High, Low, Neutral, Reverse, Park.
Drive System:
6x6 drive with automatic all-wheel drive (AWD) engagement and front/rear locking differentials for maximum traction.
Clutch Type:
CVT (Continuously Variable Transmission) with primary and secondary clutch system.
Transmission Fluid:
Polaris specific PVT fluid or equivalent. Capacity typically around 1.0-1.5 quarts (0.9-1.4 liters). Specific part number for fluid: Polaris 2204903 (check manual for exact superseded part).
Length:
Approximately 97.5 inches (247.7 cm).
Width:
Approximately 48 inches (121.9 cm).
Height:
Approximately 50 inches (127 cm).
Dry Weight:
Approximately 800-850 lbs (363-386 kg).
Payload Capacity:
Approximately 600 lbs (272 kg) on racks.
Towing Capacity:
Approximately 1500 lbs (680 kg).
Front Rack Capacity:
Approximately 100 lbs (45 kg).
Rear Rack Capacity:
Approximately 200 lbs (90 kg).
Front Tire Size:
26 x 8-12 (typical).
Rear Tire Size:
26 x 11-12 (typical).
Wheel Bolt Pattern:
Not applicable to ATVs in the traditional sense; uses hub-mounted wheels. Bolt circle diameter typically 4/110mm or similar for front and rear.
Safety Standards:
Designed and manufactured to meet industry safety standards for ATVs. Specific crash test ratings are not typically published for ATVs like passenger vehicles.
Braking:
Hydraulic disc brakes on all wheels.
Engine Braking:
Integrated engine braking through the PVT system for controlled descents.
Ergonomics:
Comfortable seating position, intuitive controls, and handguards (often standard or optional).
Operation Warnings:
Manual will contain critical safety warnings regarding proper riding techniques, protective gear, terrain limitations, and passenger restrictions.
Infotainment System:
Not applicable for this model; ATVs of this era typically did not feature advanced infotainment systems. Focus is on utility and performance.
Driver Assistance Features:
Limited driver assistance features. The primary technological focus is on the EFI system for optimized engine performance and the 6x6 drive system for traction.
Connectivity Features:
No integrated connectivity features like Bluetooth or GPS.
Diagnostic Tools:
The manual would detail procedures for using basic tools and potentially proprietary Polaris diagnostic software (if applicable for that year) for EFI and electronic systems.
Oil Change:
Every 100 hours or annually, whichever comes first. Check manual for specific break-in period recommendations.
Air Filter:
Inspect every 50 hours, clean or replace as needed. More frequent cleaning in dusty conditions.
Spark Plug:
Replace every 200 hours or annually. Specific part number typically NGK CR9EIB-9 or equivalent.
Transmission Fluid Change:
Inspect every 50 hours, change annually or every 100 hours. Check manual for specific interval.
Belt Inspection:
Inspect PVT belt every 50 hours for wear, cracks, or fraying. Replace if any damage is found or if it exceeds wear limits.
Coolant:
50/50 mixture of Polaris brand antifreeze or equivalent (ethylene glycol based) and distilled water. Capacity approximately 2.5-3.0 quarts (2.4-2.8 liters).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
CVT belts are a common wear item. Wheel bearings and ball joints are also subject to wear due to off-road use. EFI system sensors (e.g., throttle position sensor) can sometimes require cleaning or replacement.
Common Repairs:
Typical repairs include suspension component replacement, brake caliper service, PVT belt replacement, and occasional fuel injector cleaning.
Heritage:
Polaris has a long-standing reputation for innovation and leadership in the powersports industry, particularly in the ATV segment, with the Sportsman line being a cornerstone for decades.
Sportsman Line:
The Sportsman line has evolved significantly, with the 6x6 variants offering unique utility and traction capabilities that cater to specialized user needs. The 800cc EFI platform represented a significant step up in power and technology for its time.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States, primarily at their facilities in Minnesota and Iowa.
Industry Awards:
Specific awards for the 2009 Sportsman 6x6 800 EFI are not prominently documented in industry publications, but the Polaris Sportsman line consistently receives accolades for its reliability, utility, and performance in various ATV reviews and comparisons.
Consumer Ratings:
Generally well-regarded by consumers for its robust build, excellent off-road capability, and versatility for work and recreation.
