Basic Information Identification Make: Polaris Model: Sportsman 800 EFI 6x6 Touring Year: 2009 Vehicle Type: All-Terrain Vehicle (ATV) Codes Engine Code: P85 Introduction Market Position Positioning: The 2009 Polaris Sportsman 800 EFI 6x6 Touring ATV was positioned as a premium, versatile utility and recreational vehicle, emphasizing its six-wheel drive capability for superior traction and load-carrying capacity, combined with the comfort and amenities of the 'Touring' designation. Competitive Analysis Competitors: Competed against other premium 6x6 ATVs and high-displacement 4x4 ATVs from brands like Can-Am (Outlander), Arctic Cat (Prowler), and John Deere, as well as higher-end models from Honda and Yamaha. Key Features Features: 800cc High-Output EFI engine, Polaris Variable Transmission (PVT) with engine braking, 6x6 driveline with on-demand AWD, independent front and rear suspension, front rack with integrated lighting, rear cargo box, hydraulic disc brakes, electronic fuel injection, comfortable seating for two (Touring model). Manual Value Purpose: Essential tool for owners and technicians to perform maintenance, diagnostics, and repairs, ensuring optimal performance, longevity, and safety of the ATV. Manual Scope Scope: This is a comprehensive service and repair manual, intended for skilled technicians or mechanically inclined owners who wish to perform in-depth maintenance and repairs. Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Drivetrain, Suspension, Steering, Brakes, Electrical System, Cooling System, Bodywork, Chassis, Diagnostics, Maintenance, Troubleshooting, Repair Procedures Page Count Page Count: High (typically 500+ pages for comprehensive service manuals) Manual Type Manual Type: Service Repair Shop Manual Language Language: English Format Format: Digital (likely PDF), potentially available in print Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the 800cc EFI engine, including valve adjustments, piston/cylinder inspection, crankshaft and connecting rod service, timing components, and lubrication system. Fuel System: EFI system components, fuel pump, injectors, throttle body, sensors (MAP, TPS, IAT), fuel pressure testing, and troubleshooting of fuel delivery issues. Drivetrain: Front and rear differentials, sealed drive shafts, viscous all-wheel-drive (AWD) system, transmission (PVT - Polaris Variable Transmission), clutch service (primary and secondary), belt inspection and replacement, and gearcase maintenance. Suspension: Front and rear independent suspension, shock absorber adjustment and replacement, control arm inspection and service, wheel bearing maintenance, and spring specifications. Steering: Handlebar assembly, tie rod ends, steering post, and potential troubleshooting for steering play or stiffness. Brakes: Hydraulic disc brake systems (front and rear), brake caliper service, master cylinder overhaul, brake line inspection and replacement, and bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), ignition system (spark plugs, ignition coil), starter motor, lighting system, switches, fuses, and EFI control unit (ECU) diagnostics. Cooling System: Radiator, cooling fan operation, coolant types, flushing procedures, and thermostat service. Bodywork Chassis: Frame inspection, body panel removal and installation, seat assembly, rack systems, and general chassis component checks. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, gear oil), filter replacements (oil, air), spark plug replacement, belt inspection, lubrication points, and general upkeep. Troubleshooting: Diagnostic flowcharts for common starting issues, running problems, electrical faults, braking system concerns, and transmission issues, often correlating with error codes. Repair: Step-by-step instructions for component replacement, component overhaul, system diagnostics, and repair of virtually all mechanical and electrical systems on the ATV. Diagnostics: Information on using diagnostic tools (if applicable), reading fault codes, sensor testing, and systematic troubleshooting based on symptoms. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and detailed schematics. Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Print Quality: High-resolution images and clear diagrams suitable for printing. Binding Type Binding Type: N/A (Digital format); If printed, likely spiral-bound for lay-flat use. Paper Type Paper Type: N/A (Digital format); If printed, typically heavy-duty paper stock resistant to shop conditions. Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, Twin-Cylinder (V-Twin) Displacement: 760 cc (46.4 cu. in.) Bore X Stroke: 93 mm x 73 mm (3.66 in. x 2.87 in.) Cooling System: Liquid-Cooled Ignition: Electronic CDI with Digital Boost Performance Horsepower: Approx. 52 hp (varies slightly based on source) Torque: Not typically published as a single peak figure, but significant low-end torque for utility use. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or similar system Fuel Type: Unleaded Gasoline, 87 Octane or higher recommended Fuel Tank Capacity: 4.1 gal (15.5 L) Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Drive System: 6x6, with On-Demand AWD front axle activation and rear locked differential Features Clutch Type: Roller primary clutch, roller secondary clutch Final Drive: Sealed Driveshaft, Gearcase Dimensions Exterior Length: 91.5 in. (232.4 cm) Width: 46 in. (116.8 cm) Height: 50 in. (127 cm) Wheelbase: 76 in. (193 cm) Ground Clearance: 11.5 in. (29.2 cm) Weights Dry Weight: 765 lbs (347 kg) Gvw: 1330 lbs (603...