Category:
Heavy-duty utility ATV
Target Audience:
Owners, mechanics, and DIY enthusiasts requiring in-depth knowledge for maintenance and repair of the Polaris Sportsman 6X6 800 EFI.
Comparison:
The 6x6 configuration offers superior traction and load-carrying capacity compared to standard 4x4 ATVs, making it a niche but highly capable vehicle for demanding tasks.
Vehicle Focus:
Emphasis on ruggedness, all-wheel drive capability, and utility for off-road work and recreation.
Engine:
Full disassembly, assembly, inspection, and repair of the 800cc EFI engine, including top-end, bottom-end, cooling, lubrication, and fuel delivery systems.
Transmission:
Service and repair procedures for the automatic transmission, including belt replacement, clutch inspection, and gearbox maintenance.
Drivetrain:
Detailed instructions for servicing the 6-wheel drive system, including differentials, axles, CV joints, and drive shafts.
Electrical:
Comprehensive electrical system diagnosis, including wiring diagrams, troubleshooting guides for ignition, lighting, charging system, EFI, and accessories.
Suspension:
Front and rear suspension system repair, including shock absorbers, control arms, bushings, and wheel bearings.
Brakes:
Brake system service, including hydraulic lines, master cylinder, calipers, rotors, and bleeding procedures for both front and rear brakes.
Steering:
Steering system maintenance and repair, including tie rods, steering column, and any power steering components (if applicable).
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, fuel tank, and lines.
Cooling System:
Radiator, fan, thermostat, hoses, and coolant specifications.
Body And Frame:
Body panel removal, installation, and frame inspection procedures.
Maintenance:
Regular maintenance schedules, lubrication points, filter changes, and fluid checks.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues.
Repair:
Step-by-step repair instructions for virtually all mechanical and electrical components.
Disassembly Assembly:
Detailed procedures for taking apart and reassembling major components.
Technical Specifications:
Torque specifications, clearances, tolerances, and measurement guides.
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all systems.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive, covering everything from basic maintenance and fluid changes to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics.
Engine Type:
4-stroke, SOHC, 4-valve
Displacement:
760cc (approx. 800cc class)
Bore X Stroke:
Specifics available within the manual, but typical for this class.
Cooling System:
Liquid-cooled
Horsepower:
Estimated 50-55 HP (exact figures in manual)
Torque:
Specific figures available within the manual.
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Oil Type:
API SG or higher, SAE 10W-50 (check manual for specific Polaris recommendation).
Oil Capacity:
Specific capacity detailed in the manual (typically around 2-3 quarts).
Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse, Park, Engine Braking
Drive System:
6x6 AWD (All-Wheel Drive) with Lockable Front Differential
Engagement:
On-demand engagement of front axles for 6x6 capability.
Length:
Approx. 104 inches (specifics in manual)
Width:
Approx. 46 inches (specifics in manual)
Height:
Approx. 50 inches (specifics in manual)
Dry Weight:
Approx. 750 lbs (specifics in manual)
Payload Capacity:
Approx. 800 lbs (combined rider and cargo)
Towing Capacity:
Approx. 2000 lbs
Front Tire Size:
25 x 8-12 (typical, verify in manual)
Rear Tire Size:
25 x 11-10 (typical, verify in manual)
Wheelbase:
70 inches (typical for 6x6, verify in manual)
Features:
Typically basic instrumentation: speedometer, odometer, trip meter, fuel gauge, and warning lights. Advanced infotainment is not a primary feature of this utility model.
Features:
Engine braking system for downhill control, switchable AWD for traction management.
Features:
No advanced connectivity features expected for this model year and category.
Oil Change:
Recommended every 100 hours or 6 months (refer to manual for exact intervals).
Air Filter:
Inspect every 50 hours, clean or replace as needed (more frequently in dusty conditions).
Spark Plug:
Inspect and gap every 100 hours, replace as needed.
Drive Belt:
Inspect every 100 hours for wear, cracks, and proper tension. Replace as needed.
Coolant Type:
Ethylene glycol based antifreeze (e.g., Polaris Premium All-Season Antifreeze) - specific mixture ratio detailed in manual.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (verify in manual).
Differential Fluid:
Specific gear oil and capacity for front and rear differentials will be listed in the manual.
Common Wear Items:
Drive belts, suspension bushings, tie rod ends, and wheel bearings are common wear items on utility ATVs due to their demanding use.
Efi Diagnostics:
EFI systems require specialized diagnostic tools and knowledge, which this manual will provide.
Polaris Atv:
Polaris has a long history in the ATV market, pioneering many innovations and establishing itself as a leading manufacturer of off-road vehicles.
Sportsman Line:
The Sportsman line is Polaris' flagship utility ATV series, known for its durability, performance, and advanced features, with the 6x6 variants catering to specialized needs.
Manufacturing:
Polaris vehicles are primarily manufactured in the USA.
