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AVR-2106/886 Electronics Service Manual
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Basic Information Identification Make: Polaris Model: Sportsman 6X6 800 EFI Year: 2009 Product Type: Factory Service Repair Manual Format: PDF Download Introduction Market Position Category: Heavy-duty utility ATV Target Audience:...
Type: Atv
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Sportsman 6X6 800 EFI |
| Year: | 2009 |
| Product Type: | Factory Service Repair Manual |
| Format: | PDF Download |
| Introduction | |
| Market Position | |
| 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. |
| Competitive Analysis | |
| 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. |
| Key Features | |
| Vehicle Focus: | Emphasis on ruggedness, all-wheel drive capability, and utility for off-road work and recreation. |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Comprehensive repair and adjustment information for the Polaris Sportsman 6X6 800 EFI 2009 model. |
| Page Count | |
| Estimated Pages: | Extensive, likely exceeding 500 pages based on typical factory service manuals for this type of vehicle. |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| 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. |
| Procedures Included | |
| 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. |
| Technical Depth | |
| Depth: | Comprehensive, covering everything from basic maintenance and fluid changes to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Searchability: | Likely contains searchable text for efficient information retrieval. |
| Print Quality | |
| Quality: | Digital format allows for high-resolution viewing of diagrams and text. Print quality is dependent on user's printer. |
| Binding Type | |
| Binding: | N/A (Digital PDF Download) |
| Paper Type | |
| Paper: | N/A (Digital PDF Download) |
| Engine Specifications | |
| Primary Engine | |
| 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 |
| Performance | |
| Horsepower: | Estimated 50-55 HP (exact figures in manual) |
| Torque: | Specific figures available within the manual. |
| Fuel System | |
| Induction: | Electronic Fuel Injection (EFI) |
| Fuel Type: | Unleaded gasoline |
| Engine Oil | |
| 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). |
| Transmission | |
| Standard | |
| 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 |
| Features | |
| Engagement: | On-demand engagement of front axles for 6x6 capability. |
| Dimensions | |
| Exterior | |
| Length: | Approx. 104 inches (specifics in manual) |
| Width: | Approx. 46 inches (specifics in manual) |
| Height: | Approx. 50 inches (specifics in manual) |
| Weights | |
| Dry Weight: | Approx. 750 lbs (specifics in manual) |
| Payload Capacity: | Approx. 800 lbs (combined rider and cargo) |
| Towing Capacity: | Approx. 2000 lbs |
| Wheels Tires | |
| 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) |
| Safety Features | |
| Ratings | |
| Atv Safety: | ATVs are inherently off-road vehicles and require proper safety gear and training. The manual will detail safe operating practices. |
| Active Features | |
| Braking System: | Hydraulic disc brakes front and rear. |
| Passive Features | |
| Lighting: | Dual headlights, brake lights, and tail lights. |
| Ergonomics: | Designed for control and comfort during operation. |
| Technology Features | |
| Infotainment | |
| Features: | Typically basic instrumentation: speedometer, odometer, trip meter, fuel gauge, and warning lights. Advanced infotainment is not a primary feature of this utility model. |
| Driver Assistance | |
| Features: | Engine braking system for downhill control, switchable AWD for traction management. |
| Connectivity | |
| Features: | No advanced connectivity features expected for this model year and category. |
| Maintenance | |
| Service Intervals | |
| 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. |
| Fluid Specifications | |
| 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. |
| Known Issues | |
| 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. |
| Vehicle History | |
| Brand Heritage | |
| 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. |
| Model Evolution | |
| 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. |
| Production | |
| Manufacturing: | Polaris vehicles are primarily manufactured in the USA. |
| Awards & Recognition | |
| Recognitions | |
| Atv Awards: | Polaris Sportsman models have historically received accolades for their utility, performance, and innovation in the ATV market. Specific awards for the 2009 800 EFI 6x6 would be detailed in industry publications or recalled by owners. |