Polaris 800 manual

PMS 419 Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. Owner's Manual for Maintenance and Safet y Spor tsman Forest 800[...]

1 WELCOME Thank you for pu rchasing a POL ARIS vehicle, and welcome to our world-wide family of POLARIS owne rs. W e proudly prod uce an excit- ing line of utility and recreational product s. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® Always follow the instructions and recommendations[...]

2 POLARIS, THE W A Y OUT and SPO R TSMAN a re registered trad emarks of POLARIS Industries Inc. Copyright 201 1 POLARIS Sales Inc. All inform ation contained within this publication is based on the latest product information at the time of publicati on. Due to constant improvements in the design and quality of production components, some minor disc[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Winch Guide . . . . . . . . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. W ARNING A W ARNING indicates a hazardous[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. A POLARIS A TV is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicle s, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuver[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARI S key blank (using your k ey number) and mating it with one of your existi ng keys. The ignition swit[...]

7 SAFETY Safety T raining Never oper ate this veh icle without proper instruction. T ake a training course. For more information ab out safety , contact an authorized POLARIS dealer or visit the POLARIS web site at www .polarisindustries.com.[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of in jury . Helmet W ea ring a helmet can prevent a sever e head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or excee ds estab- lished safety standards. Approved helmets in[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face sh ield. POLARIS recommends wearing approved Personal Protective Equipm ent (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make sur[...]

10 SAFETY Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’s manual. See the OPERA TION section of the owner ’s manual for proper operating proce dures. Operating Without Instructi[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- el[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Oper[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are designed for o ff-road use. If it's unavoi[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the footrests during operatio n can reduce your abili ty to control th e vehicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Neve[...]

15 SAFETY Safety W arnings Descending Hill s Improper ly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hi lls as described in the owner's manual. NOTE: A special technique i s required when braking while traveling down- hill. See page 55. • Always descend a hil[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed whe n climbing a hill. If all forward speed is lost: • Keep body weight up hill. • Apply the brakes. • Lock the parking brake when fully stopped. [...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain. Always use ex tra caution on roug h, slippery or loose terrain. Op[...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a coll ision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 59. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When it's safe to proce[...]

19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. A void operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operati ng proce dures as outlined i[...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this A TV . • Cargo should be p roperly distributed and securely attached. • Reduce speed when carrying cargo or[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a dama ged A TV can result in a n accident. After any overturn or accident, have a qualifi ed service dealer inspect the entire ma chine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active vehicle[...]

22 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or graphi[...]

23 SAFETY Safety Labels and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause loss of co ntrol. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 515 lbs. (234 kg) Discretionary W arning W ARNING [...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. Age 16 W arning W ARNING Operating this A TV if yo u are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under [...]

25 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o p revent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whi ch can result in serious injury or dea[...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, which may result in seri ous[...]

27 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main Key Switch Use the main[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr operly operating throttle controls could cause an accident. Never start or oper ate an A TV that has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of th[...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Never operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before ope rating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear [...]

30 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid An over-full master cyl inder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the a[...]

31 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lo ck, squeeze and release the brake lever [...]

32 FEA TURES AND CONTROLS Auxiliary Foot Brake Never back down a hill. Applying the auxi liary brake when backing down a hill may cause rear tipover , which could re sult in serious injury or death. Use caution when ap plying the auxiliary brake. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may skid and slid e [...]

33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a com- plete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engin e speed [...]

34 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Whee l Drive syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two- wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD, the demand drive [...]

35 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes a[...]

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cluster ma y have shut of f to protect the el[...]

37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center St andard Modes Use the MODE button to toggle thro ug h the mode options. Th e reverse override button is also the MODE bu tton. See page 26. The transmis sion cannot be in reverse wh en using this feature. Odometer Mode The odomete r records the m iles traveled by the A TV . T r[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch off an d on. Any move - ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Sc reen V iew the tachometer to check engine speed. A WD Diagnos tic Screen The gauge ind icates whether or not current is flowing through the all- wheel-drive coil. This screen [...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center[...]

41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your POLARIS dealer for all major repairs. See page 43 for Blink Co des and Failu re Descriptions. Use the follow- ing procedure to downlo ad blink codes (failure codes) from the EFI module[...]

42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (inj ector , fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in t[...]

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code Failure Description 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System V oltage Low 31 System V oltage High 36 Ignition Coil A Prim/Sec Circu[...]

44 OPERA TION Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new PO LARIS A TV is the first ten hours o[...]

45 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 76. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

46 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before ea ch use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 29 84 Brake fluid Ensure pro[...]

47 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. See page 7. 2. Do not allow anyone und er 16 year s of age to operate this ve hicle. Do not allow anyone w ith cognitive or physical disabi lities to oper - ate this ve hicle. 3. Never carry a passenger on this A TV . 4. Engine exhaus[...]

48 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ride. Fin d out where the de signated riding areas are by con- tacting your POLARIS dealer , a loc al riding club or local officials. Help keep[...]

49 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. Sit on the vehicle and move the eng[...]

50 OPERA TION Driving Procedures 1. W ea r a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the parking brake. 7. Slow[...]

51 OPERA TION T urning the V ehic le Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direc- tion of the tur[...]

52 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage A WD before wheels begin to lose traction. NOTICE: Severe [...]

53 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter - rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25  maximum). 3. Always check the terrain care fully before ascending an[...]

54 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A voi d crossing the side of a steep hill. 3.[...]

55 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25  maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the brakes too firmly may cause the rear wh[...]

56 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left[...]

57 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recom- mended depth eq ual to the bot- tom of the footrests. Follow these procedures when operat- ing through wa ter: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have grad ual inclines. 3. A void operating[...]

58 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamilia[...]

59 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

60 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo imp roperly can alte r vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. [...]

61 OPERA TION Hauling Cargo Never exceed the weight capaci- ties specified for your A TV on warning labels an d in the speci- fications section of this manual. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as poss ible. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 l[...]

62 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side.[...]

63 WINCH GUIDE The responsibility for safe operation of the winc h ultimately rest s with you, the operator . Read and underst and all safety precautions and oper- ating instructions before operatin g the winch. Careless operation ca n result in serious injury . DO NOT use the winch to lift or move people. Winch Safety Precautions 1. Be alert. Do n[...]

64 WINCH GUIDE Winch Cable Care 1. The life of a cable is directly rela ted to the care it receives. The wire cable on a new winch (and any replacement cables ) must be re- spooled under a minimum o f a 100-lb. (45.4-kg) load before use. Failure to do this will result in cabl e damage. 2. Inspect all cable before use. Mashed, p inched, frayed or ki[...]

65 WINCH GUIDE Winch Prep aration and Inspection Wear heavy leather gloves whenever handling cable. Do not all ow the cable to slip thro ugh your hands, even with gloves on. When handling the hook, always use a handsaver . Never place fingers into the hook. Placing fi ngers in the hook could result in injury . Inspect the switch and wiring for crac[...]

66 WINCH GUIDE Winch Rigging T ake your time when rigg ing and use extr a caution. Improper rigging can result in injury in addition to damage to the vehicle and equipme nt. Never handle the cable or rigging w hile another per so n is at the control switch. 1. Use a nylon s ling to attach the ca ble to an anchor point. CAUTION! Do not attach the ho[...]

67 WINCH GUIDE Winch Operation NOTICE: This winch is designed for inte rmitt ent use. Prolonged use may result in damage due to overheating. 1. Use common sense. 2. T ake your time. 3. Think through the situation. 4. Pay attention to what is going on when you are winching. 5. DO NOT overheat the winch motor . During extended winching, stop and f ee[...]

68 WINCH GUIDE Winch Operation 13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will signific antly reduce the pulling power of your winch. If the winch is still no t capable of pulling the load, use a snatch block. 14. Never pull with less than fi ve wraps of cable on the spool. 15. Inspect the condition of th[...]

69 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements. S p ark Arrester Y our POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester r[...]

70 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

71 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and cause an accident, wh ich may result in se rious injury or death. Always have an authorized POLA RIS dealer perform these services. Maintenance Chart Key  Perform these operations more often for vehic les subjec[...]

72 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first.  Perform these procedures more often fo r vehicles subjected to severe use.  Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  S tee[...]

73 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.  Throttle Cable/ ETC Switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary Throttle Body Intake Duct 50 H 6 M 50[...]

74 MAINTENANCE Periodic Maintenance Chart  Perform these procedures more often fo r vehicles subjected to severe use.  Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn[...]

75 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 70. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be neede[...]

76 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a si milar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W -50 oil. Follow the manufactur er's recommendations for ambient temperature operation. See[...]

77 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 70. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to warm up at idle for two to three min- utes. 3. Stop the [...]

78 MAINTENANCE Engine Oil Oil and Filter Change 1 1. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o -ring is in good condition. 12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn. 13. Remove the dipsti[...]

79 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. See page 124 for the part numbers of POLARIS products. The fill plug is located on the left si de of the A TV , under the[...]

80 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the oil level. 3. Add the recommend ed fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. T orque to specification. Oil Change 1. Remove the fill plug. 2. Place a drain pan under t[...]

81 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Ma intenance Chart beg inning on page 70. W e rec- ommend the use o f Demand Drive Plus Fluid. Use of other fluids may result in improper operation of comp onen ts. See page 124 for the part numbers of POLARI[...]

82 MAINTENANCE Cooling System The engine coolant level is controll ed, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expa nding (heated) excess coolant is forced out of the e[...]

83 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recove[...]

84 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops. If the fluid le ve l is low and the diaphragm is not extended, a leak is lik[...]

85 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attempt to adju st tie rod alignment. All tie rod a djustments should be perfo[...]

86 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock abs orber spring is adjuste d by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer . Handlebars The handlebars can be adjusted for rider p[...]

87 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your POLARIS dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and s[...]

88 MAINTENANCE S teering Assembly The steering assembly o f the A TV sh ould be checked period ically for loose nuts and bolts. If loose nu ts and bolts are found, see yo ur POLARIS dealer for service before operating the vehicle. Side Panel Re moval 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull[...]

89 MAINTENANCE Ti r es Operating your A T V with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al ways[...]

90 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking brake . 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. T orque the wheel[...]

91 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main [...]

92 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a co mpartment on the top of the access door . 1. Open the front box cover .[...]

93 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and replace burn ed out lamps promptly . Alway s make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halog en lamp, don[...]

94 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in P ARK. 2. Measure the distance from the floo r to the ce[...]

95 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. T ilt the headlamp upward or down- ward. 3. Tigh ten the screw . Phillips Screw[...]

96 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedometer harnes ses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a s[...]

97 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headlamp . 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harness clock- wise to secure th[...]

98 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications sect ion beginning on page 1 22 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs t o specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Sp [...]

99 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Sp ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator ti[...]

100 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the A TV to dry land or a[...]

101 MAINTENANCE S p ark Arrester Failure to heed the following warnings whil e servicing the spark arrester could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. N[...]

102 MAINTENANCE PVT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balanc[...]

103 MAINTENANCE PVT System PVT Operation The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the fly- weights also increases. This, in tu rn, increases the amount of pinch applied to the drive belt. Similarly , if the [...]

104 MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is subs tantially reduced by usin g low range while operating at low gr ound speeds. Reducing the tempera- ture inside the clutch cover greatly extends the life of the PVT compo- nents (belt, cover , etc.). When T o Use Low Range and High Range PVT Drying There may be [...]

105 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains su[...]

106 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover (if equipped). 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not t[...]

107 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 109 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in [...]

108 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to mainta in a full charge. POLARIS reco[...]

109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent dama ge from leak- ing or spilled electroly te during charging. See page 106. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.27[...]

110 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. St ate of Charge V olt age Action Charge Time (Using constant current charger @ standa rd amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%[...]

111 MAINTENANCE Cleaning and St orage W ash ing the V ehicle Keeping your POLARIS vehicle clea n will not only improve its appear - ance but it can also extend the life of various componen ts. NOTICE: High water pr essure may damage compon ents. POLAR IS recommends washing the vehicle by han d or with a garden hose, using mild soap. Certain product[...]

112 MAINTENANCE Cleaning and St orage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or com[...]

113 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chr[...]

114 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S t arting the engine during the storage period will di sturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and then clean the vehic le as recommended. See page 1 1 1. St a[...]

115 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommended in the Periodic Maintenance Char t beginning on page 70. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid loo ks[...]

116 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 70. Battery Maintenance Remove the battery and rechar ge it as outlined o n page 109. S tore the battery in a cool, dry place. Storage Area/Covers [...]

117 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PA R K . 3. Lock the parking brake . 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope. Do no t attach tie strap[...]

118 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 56). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequently [...]

119 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breaker or blown fus e Reset the breaker/Replace fus e Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k a[...]

120 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs In[...]

121 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Repla ce with new fuel Fouled or defective spark plugs Inspec t, clean and/or replace spark[...]

122 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN FOREST 800 Maximum W eight Capacity 515 lbs. ( 234 kg) (includes operator , cargo, accessories) Dry W eight 741 lbs. (336 kg) +/- 7%, b ased on configuration Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3 .6 qts. (3.4 l) Demand Drive Fluid Ca pac[...]

123 SPECIFICA TIONS Clutching SPORTSMAN FOREST 800 T ransmission Automatic PVT wi th E-Z Shift H/L/N/R/ P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, High 8.28:1 Drive Ratio, Front 3.82:1 T ires/Pressure, Front Off Road S tyle, Deep Tread Design Size 25x8-12 / 5 psi (34.5 KPa) T ires/Pressure, Rear Off Road S tyle, D[...]

124 POLARIS PRODUCTS Part Number Description Engine Lubr icant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performa nce Synthetic 2W -50 4-Cyc le Oil (gal./3. 8 l) Gearcase / T ransmission Lubricants 2878068 AGL PLUS T ran smission Fluid (qt./.95 l) 2878069 AGL PLUS T [...]

125 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the POLARIS All T errain V ehicle (A TV) against defects in ma terial or workmanship. This warranty covers the parts and labor charges for repair or replacement of defect ive parts which are covered by this[...]

126 W ARRANTY LIMIT A TIONS OF W ARRANTIE S AND REMEDIES Warranty does not apply to pa rts exposed to friction surfaces, stresses, environmental conditions and/or contaminat ion for which they were not designed or not intended, including but not limited to the following items: W arranty applies to the product only and does not allow for coverage of[...]

127 W ARRANTY LIMIT A TIONS OF W ARRANTIE S AND REMEDIES This warranty does not cover the use of unauthor ized lubricants, chemic als, or fuels that are not compatible wi th the A TV . The exclusive remedy for breach of this warran ty shall be, at POLARIS' exclusive option, repair or replacement of any de fe ctive materials, or components or p[...]

128 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

129 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

130 INDEX A Accessories . . . . . . . . . . . . . . . . . . 116 Air Filte r . . . . . . . . . . . . . . . . . . . . . 91 All Wheel Drive System . . . . . . . . . 34 Auxiliary Foot B rake . . . . . . . . . . . . 84 AWD Switch . . . . . . . . . . . . . . . 26, 34 AWD System . . . . . . . . . . . . . . . . . . 34 B Battery . . . . . . . . . . . . . . [...]

131 INDEX G Gasoline Ha ndling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . . 33 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9 H Hand Brake . . . . . . . . . . . . . . . . . . . . 84 Handlebar Adjustme nt . . . . . . . . . . . 86 Hauling Cargo . . . . . . . . . . . . . . . 60-61 Headlight Housing Rep[...]

132 INDEX S Spark Plug Torque Specification . . . 98 Spark Plugs . . . . . . . . . . . . . . . . . 98-99 Specifications, 800 EFI . . . . . . . . . 123 Spring Adjustment, Rear Shock . . . 86 Starting the Eng ine . . . . . . . . . . . . . 49 Steering Ass embly . . . . . . . . . . . . . . 88 Storage . . . . . . . . . . . . . . . . . . . 111-116 Storag[...]

Before you operate this vehicle, read the owner ’ s manual For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923428 Rev 02 Printed in USA *9923428 * PMS 419[...]