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. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 800 EFI HO Model Variant: 6x6 Model Years Covered By Manual: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Codes Engine Code Indicator: EFI HO 👋 Introduction Market Position Segment: Heavy-Duty All-Terrain (ATV) Utility Vehicle Competitive Analysis Key Competitors: Honda Foreman, Yamaha Kodiak, Can-Am Outlander (during its respective model years) Key Features 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 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Page Count: Extensive (typical for full workshop manuals, often 500+ pages, exact count not specified but implies comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered 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 Procedures Included 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 Technical Depth Depth: Comprehensive (covering routine maintenance to complete engine and transmission rebuilds, including electronic diagnostics) 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Clarity: High Resolution (indicated by 'illustrated with clear step-by-step instruc...') Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 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. Performance 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 System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Ignition Ignition System: Electronic CDI with Digitalis Ignition Control Cooling Cooling System: Liquid-Cooled 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Gear Selection: High, Low, Neutral, Reverse, Park Optional Drive Modes: 2WD/AWD On-Demand (selectable, plus the inherent 6x6 drive) Features Final Drive: Shaft Drive 📐 Dimensions Exterior Length: Approx. 103 in. (varies slightly by year) Width: Approx. 46 in. (varies slightly by year) Height: Approx. 50 in. (varies slightly by year) Cargo Front Rack Capacity: 100 lbs (45.4 kg) Rear Rack Capacity: 200 lbs (90.7 kg) Weights 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. 🛡️ Safety Features Ratings Rollover Protection: N/A (ATVs do not have standardized crash ratings like cars. Operator awareness and safety gear are paramount.) Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Engine Braking: Integrated engine braking via PVT system Passive Features Lighting: Dual Halogen Headlights, Tail Light, Brake Light Ergonomics: Ergonomic seating position, hand grips, footwells for rider comfort and control. 💡 Technology Features Infotainment Dashboard: Digital/Analog instrument cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, and warning lights. Driver Assistance Traction Control: Electronic 6x6 AWD system for enhanced traction in challenging terrain. Connectivity Accessories: Provision for accessory electrical connections (winch, lights, etc.) 🔧 Maintenance Service Intervals Oil Change: Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact intervals). Air Filter Cleaning: Every 25...