Polaris 2005 Sportsman 800 EFI manual

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P art No. 9917720 Rev 01[...]

A car d containing im port ant A TV saf et y inf ormat ion should be at t ached to t he owner ’s manual on the next page. If you cannot locate t his c ard, or if it has been rem oved, please call 1-800- 342-3764 f or ass ist ance. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive [...]

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2 Copyri ght 2004 Pola r is Sa l e s I nc . All i nfor ma t ion c ont a ine d wi t hin t hi s publi c at i on i s bas e d on the l a te st produc t inf or ma t ion at t he t im e of publi c a ti on. Due to cons tant imp ro vem ents in the desig n an d q uality o f pr oduct ion com ponent s , s ome mi nor discrep an cies may result betw een th e act[...]

3 WELC OME Thank you for purcha sing a Polar is vehicle , and welc ome to our world-w ide family of Polar is owners. W e proudly produce an exc iting line of utility a nd re cr ea tional pr oducts. Polaris R ecreational V ehicles S Snowmobiles S All-te rr ain ve hicle s (A TVs) S W atercraft S RANGER utility vehicle s S V ict ory m ot orcy cles W e[...]

4 VEHICLE IDE NTIFICATION NUMBERS Recor d your A TV’ s identifica tion number s and key numbe r in the spaces prov ided . R emo ve t he sp are key an d s to re it in a s afe pl ace. Y our key can be duplica ted only by mating a Polaris ke y blank with one of your existing ke ys, so if both keys ar e lost, the ignition switc h mus t be replaced . [...]

5 TABLE OF CONTENTS WELCOM E 3 ........................................ VEHICLE I DENTI FICA T IO N NUMBERS 4 ............... SAFET Y 6 .......................................... FEA TURES AND CONT ROLS 32 ...................... OPER A TION 46 ..................................... EMISSI ON CONT RO L SYSTEM S 63 ................... MAINTENANCE AND [...]

6 SAFE TY Safety D ecals and Locations W arning decals h ave been placed on th e A TV for your protecti on. R ead and fo ll ow t he i ns tru cti on s of the decal s o n t he A TV careful ly . If any of the decals depi cted in thi s manual differ from t he decals on your A TV , al ways read and f oll ow the i ns truct i ons of th e decal s on the A [...]

7 SAFE TY Safety D ecals and Locations A TTE NTION S Operat ion of this v ehic le wit hout the air filt er element will s ev erely damage the engine. S Clean pre- filter element often, mor e frequent c leaning requir ed in dus ty conditi ons. D o not operat e vehic le w ithout pre-filt er . 7172921 IMPRO PER TI RE PRESSUR E OR O VERLO ADI NG can ca[...]

8 SAFE TY Safety D ecals and Locations S DO NOT TOW FROM RA CK OR BUMPE R. V ehicle damage or tipov er may res ult c aus ing s ev ere injury or death. T ow only f rom tow hook s or hitc h. S Max R ac k Loads : F ront 100 lbs . (45 k g) R ear 200 lbs . (91 k g) 7172749 S Moving parts haz ard under belt-c lutch guard. T o prev ent ser ious injury , d[...]

9 SAFE TY Safety D ecals and Locations ALL WHEEL DRIVE SWITCH Do not push s witch t o engage AW D if the rear wheels are s pinning. This may cause severe drive shaf t and clutc h damage. See your Owner ’s Manual. 7079780 7170509 TRAILER MAX WEIGHT : 1500 LBS. ( 682 KG ) O N L EVEL GR OUND 850 LBS. ( 386 KG ) UP TO 15 ° GRADE HITCH MAX. VERTICAL [...]

10 SAFE TY Safe R iding Gear Always wea r clothing suite d to the t ype of riding. A TV riding requires specia l protective c lothing for comf ort and to reduce the c hanc e of injury . 1. Helmet Y our helmet is the most important pie ce of protec tive gea r for sa fe riding. A helm et can preven t a s evere head inj ury . Sel ect an appr oved h el[...]

11 SAFE TY Operator S afety W ARNING Failur e to f ollow the war nings cont ained in t his manual c an result in severe injur y or death. A Polar is A T V is not a toy and can be hazardous to operat e. This vehicle handles differently than ot her vehic les, such as motorcycles and cars. A collision o r rollover can occur quickly , even during r out[...]

12 SAFE TY Operator S afety The following signa l words and symbols a ppea r throughout this manual a nd on your vehic le. Y our sa fe ty is involved whe n these wor ds and symbols are use d. Become fa miliar w ith their mean ings before rea ding the manual. The safety aler t sy mbol , on your vehic le or in t his manual, alert s you to t he pot en[...]

13 SAFE TY Operator S afety W ARNING Serious injury or deat h can res ult if you do not follow thes e instr uct ions and proc edures, which are out lined in f urt her det ail within your owner ’ s manual. S Read this ma nual a nd all labe ls car ef ully , and f ollow the ope rating proce dures de scribe d. S Never ope rate a n A TV without proper[...]

14 SAFE TY Operator S afety S Always have th e A TV in spect ed by an au th ori zed Po lari s deal er if it’ s been i nvolved i n an accident. S Neve r oper ate on hills too steep for the A TV or for your a bilities. Pra ctic e on smalle r hills befor e atte mpting lar ger hills. S Always fo llow proper pr oce dure s for climbing hills. Check the[...]

15 SAFE TY Operator S afety S W et brake s may have reduc ed stopping a bility . T est the brak es af ter lea ving wate r . If ne ce ssar y , apply the m lightly sever al time s to allow frict ion t o dry o ut t he pads . S Always chec k for obstacle s or people behind the A TV before ope rat- ing i n revers e. When i t’ s s afe to pro ceed in re[...]

16 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V wit hout proper inst ruc tion. WHA T CAN HAPPEN The r isk of an accident is great ly incr eased if the operat or does not know how to operat e the A TV proper ly in differ ent s ituat ions and on different types of t errain. HOW TO A VOID THE HAZARD Beginning and inexper[...]

17 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an A T V . WHA T CAN HAPPEN Carry ing a passenger great ly reduces t he operat or ’ s ability t o balance and contr ol t he A TV , whic h could caus e an accident and injury t o the oper ator and/or pas senger . HOW TO A VOID THE HAZARD Never c arry a passenger . T h[...]

18 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V on public str eets , roads or highways. WHA T CAN HAPPEN The A T V c ould collide wit h another v ehicle. HOW TO A VOID THE HAZARD Never oper ate t he A T V on any public st reet , r oad or highway , including dirt and gravel r oads. In m any st at es it ’s illegal to [...]

19 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V af ter consuming alc ohol or drugs . WHA T CAN HAPPEN Consumpt ion of alc ohol and/or drugs could s eriously affect operat or judgment . Reaction t ime m ay be slower and operator balance and perc eption c ould be affect ed. Consuming alc ohol and/or drugs befor e or whil[...]

20 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failur e to inspec t t he A T V bef ore oper ating. Failure t o proper ly maint ain t he A T V . WHA T CAN HAPPEN Poor m aintenanc e increas es t he possibilit y of an accident or equipment damage. HOW TO A VOID THE HAZARD Always ins pect your A T V bef ore eac h use t o make s ure it ’s in [...]

21 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failur e to use ex tr a caut ion when operat ing the A T V on unfamiliar t err ain. WHA T CAN HAPPEN Unfamiliar terr ain may contain hidden rocks, bumps, or holes t hat c ould cause l oss of cont rol or overt urn. HOW TO A VOID THE HAZARD T ravel slowly and use ext ra caut ion when operat ing [...]

22 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD T urning improper ly . WHA T CAN HAPPEN Im proper t urns could cause loss of cont rol and lead t o a collis ion or overt urn. HOW TO A VOID THE HAZARD Always follow proper pr ocedures for t urning as described in t he owner ’ s manual. Prac tic e turning at slow speeds before at t empt ing t[...]

23 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Climbing hills im properly . WHA T CAN HAPPEN Impr oper hill c limbing could cause los s of control or overt urn. HOW TO A VOID THE HAZARD Always f ollow proper procedur es f or clim bing hills as desc ribed in the owner ’s manual. Always c heck t he t errain c aref ully bef ore asc ending a[...]

24 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill impr operly . WHA T CAN HAPPEN Impr operly descending a hill could caus e loss of contr ol or overt urn. HOW TO A VOID THE HAZARD Always f ollow proper procedur es f or t raveling down hills as des cribed in t he owner ’ s manual. NOT E: A special t echnique is required w[...]

25 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Impr operly c ross ing hills and turning on hills . WHA T CAN HAPPEN Im properly crossing or turning as hills could c ause loss of cont rol or overt urn. HOW TO A VOID THE HAZARD N e v e ra t t e m p t t ot u r nt h eA T V around on any hill unt il you’v e mast ered t he tur ning tec hnique [...]

26 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Stalling, rolling back wards or improper ly dismount ing while climbing a hill. WHA T CAN HAPPEN The v ehicle could ov ertur n. HOW TO A VOID THE HAZARD Maint ain steady speed when climbing a hill. If all forwar d speed is lost: Keep your weight uphill. Apply t he brakes . Lock t he park ing b[...]

27 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Im properly operating over obstac les. WHA T CAN HAPPEN Oper ating over obstac les could c ause loss of cont rol or overt urn. HOW TO A VOID THE HAZARD Befor e operat ing in a new area, check f or obs tac les. Avoid operating ov er large obs tac les suc h as roc ks and f allen tr ees when poss[...]

28 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN HAPPEN T ires may f loat, causing loss of trac tion and loss of c ontr ol, which could lead t o an accident or over turn. HOW TO A VOID THE HAZARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er . I f [...]

29 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Operat ing t his A T V wit h impr oper t ires, or wit h improper or uneven t ire pres sure. WHA T CAN HAPPEN Use of i mproper tires, or operat ion of the A T V wit h impr oper or uneven t ire pres sure, could cause l oss of contr ol or acc ident. HOW TO A VOID THE HAZARD Always us e the s ize [...]

30 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Over loading the A TV or c arry ing/t owing car go improper ly . WHA T CAN HAPPEN Over loading and towing c an cause c hanges in vehic le handling, which could lead t o loss of cont rol or an ac cident . HOW TO A VOID THE HAZARD Never ex ceed the s tat ed load capac ity for t his A T V . Cargo[...]

31 SAFE TY Operator S afety W ARNING Oper ating a damaged A TV can r esult in an accident with ser ious injury or death. A ft er any overt urn or ac cident , hav e a qualified serv ice dealer ins pect the entir e machine f or pos sible damage, including (but not limit ed t o) brak es, throt t le and steer ing systems. W ARNING Safe oper ation of th[...]

32 FEATURES AND CONTROLS Engine E lectri cal Switches W ARNING Act ivat ing the ov erride s witc h while the t hrot t le is open can c ause loss of contr ol, r esult ing in sever e injury or death. Do not activat e the over ride swit ch while t he t hrot tle is open. Mod e/Rev erse O verri d e Sw itch (1) - This vehic le is e quipped with a reve rs[...]

1 33 FEATURES AND CONTROLS W ARNING Operat ing an A T V wit h st ick ing or impr operly oper ating t hrot t le contr ols c ould cause an acc ident and lead t o sev ere injury or death. Never s tart or operat e an A T V wit h a st ick ing or impr operly operat ing throt tle. Always c ontac t your dealer f or ser vice if t hrot t le problems ar ise. [...]

34 FEATURES AND CONTROLS Light Sw itches The light switch is loca ted on the le ft handle bar . It’ s used to turn the lights on and of f and to switch the lights f rom HI to LO. NOT E: T he lights won’t wor k unless t he key is in the ON posit ion and the auxiliar y shut -off switc h is in t he RUN posit ion. W ARNING Oper ating t he A T V on [...]

35 FEATURES AND CONTROLS Master Cylinder The brake f luid in t he master cylinde r (1) , which is loca ted on the left handle bar , should be chec ked before each ride. Th e flu id level can be seen thr ough an indic ator window (2) on the top of the master cylinde r . This eye wil l app ear dark whe n the fluid le vel is full. Whe n fluid needs to[...]

36 FEATURES AND CONTROLS Park in g Bra ke W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an acci dent and serious injur y or death. Alway s check t o be sure t he park ing brake is disengaged before oper ating. Setting the Par king Br ake 1. Place the tra nsmission in park. 2. S q ueeze and releas e th e brake [...]

37 FEATURES AND CONTROLS Auxiliary Brake W ARNING Aggres sively applying the auxiliar y brak e when backi ng down a hill may c ause rear tipover, which could res ult in s erious injur y or death. Use caut ion when applying t he auxiliary brake. Do not aggress ively apply the auxiliary brake when going f orward. T he rear wheels may ski d and slide [...]

38 FEATURES AND CONTROLS Automatic T ransm ission Gear Selector The transmission gea r selec tor (1) is located on the right side of the vehicle . H: High Gear L: Low Gear N: Neutral R: Rev er se P: Par k T o shift into HIGH or P ARK, you must first apply the auxilia ry bra ke to activa te the high/pa rk loc k-out mec han ism. When shifting out of [...]

39 FEATURES AND CONTROLS All Wheel D r ive (A WD) S ystem Pol aris 4 -wheel dri ve A TVs are equipped w ith a unique , Po lari s-excl us iv e, On-Dem and A ll Whe el Drive s ystem, which is acti vat ed by t he A WD swi t ch (1) on the right handleba r . When the s w i t c hi so f f ,t h eA T Vi si n two-w hee l drive at all times. When the switc h [...]

40 FEATURES AND CONTROLS In st ru men t C lu st e r Y our A TV is equipped w ith an instru ment cluste r that se nses ve hicle speed from the r ight front whe el. The instrument c luster measure s distanc e in mile s as we ll as hours of opera tion. It also includes a reve rse spee d limiter f unction tha t limits the A TV’ s speed to approxima t[...]

41 FEATURES AND CONTROLS In st ru men t C lu st e r Ride r Infor ma tion Center The r ider inf orma tion ce nter is locate d in the instr ument c luster . All segmen ts will light up for 2.5 seconds a t star t-up. NOT E: I f t he inst rum ent c lust er f ails t o illuminat e, a bat t ery over- volt age may hav e occur red and t he inst rument clust[...]

42 FEATURES AND CONTROLS In st ru men t C lu st e r Ride r Infor ma tion Center The r ider inf orma tion ce nter ha s 4 standa rd mode s: Mode 1 - Odometer Mode 2 - T ripme ter Mode 3 - T otal Service Hours Mode 4 - T achome ter The reve rse ove rride button on the left handleba r is also the mode button . NOT E: I f us ing the m ode butt on t o pr[...]

43 FEATURES AND CONTROLS In st ru men t C lu st e r Ride r Infor ma tion Center Diagnos tic Mode The diagnostic mode is for infor mational purpose s only . Please re turn your A TV to your dea ler f or all major re pair s. As long as the gauge is in the diagnostic mode, t he wrenc h icon will re main lit. T o leave the dia gnostic mode , turn the k[...]

44 FEATURES AND CONTROLS In st ru men t C lu st e r Ride r Infor ma tion Center Diagnos tic Mode Screen 5: P rogra mmable se rvic e interv al The purpose of the progra mmable se rvic e interva l is to provide the consumer a nd dea ler with a conve nient reminde r for routine maintena nce . When your vehicle le ave s the factor y , this featur e is [...]

45 FEATURES AND CONTROLS In st ru men t C lu st e r Ride r Infor ma tion Center Spe cia l EFI Di agnos tic Mode The EFI diagnostic mode is for informa tional purposes only . Please see your Polar is dealer f or all major r epa irs. T o download blink codes (fa ilure code s) from the EFI module: 1. Place the transmission in P ARK, t urn the e ngine [...]

46 OPERATION Fuel Safety W ARNING Gas oline is highly fla mm a ble and ex plosiv e unde r ce rt ain conditi ons. Always exercise ex tr eme caut ion whenever handling gasoline. Always refuel wit h the engine s topped, and outdoor s or in a well ventilat ed area. Do not sm oke or allow open flames or sparks in or near t he area where ref ueling is pe[...]

47 OPERATION Br eak-In Per iod The bre ak- in period f or your ne w Polar is A TV is defined a s the fir st ten hours of opera tion, or the time it ta kes to use the first two full tanks of gasoline. No single ac tion on your pa rt is as importa nt as following the proce dure s for a proper bre ak- in. Care ful treatme nt of a new engine will resul[...]

48 OPERATION Pr e -Ride Inspection W ARNING If a proper inspec tion is not done bef ore each us e, s evere injur y or deat h could res ult. Alway s inspec t t he vehic le befor e each use to ens ure it ’s in proper operat ing condit ion. Pre - Ride Chec kl ist Item Remarks See Page Brake system / lever t r avel Ensure proper oper at ion 34, 78 Br[...]

49 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains pois onous car bon monoxide and c an cause los s of consciousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. 1. Position the vehicle on a leve l surfac e with the tra nsmission in P ARK. 2. Lock the park bra ke, sit on the vehicle and tur[...]

50 OPERATION Hauling Cargo Y our A TV has bee n designe d to car ry or tow a cer tain a mount of load. Always re ad a nd understa nd the load d istribution wa rning labe ls on the vehi cl e, and n ever exceed t he wei ght capac ities outlined in the speci fi cati ons sect io n of th e owner ’ s man ual an d on th e safet y decals . Car go we ight[...]

51 OPERATION Hauling Cargo W ARNING Hauling cargo im properly can alter v ehicle handling and may cause los s of c ontr ol or brak e inst ability and result in serious injury or deat h. Always f ollow these prec autions when hauling cargo: REDUCE SPEED AND ALLOW GREA T ER DIST ANCES FOR BRAKING WHEN H AULING C ARGO. CARGO WE IG HT DIST RIB UTI O N [...]

52 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both feet on the f ootrests a nd both hands on the handleba rs. 2. Start the e ngine a nd allow it to warm up, then shift the tran smission into gea r . 3. Check your surr oundings and determine your path of tra vel. 4. Relea se the parking brake . 5. Slowly depre ss the throttle w[...]

53 OPERATION Driving Safely Making T urns Y our A TV is equipped with a sol i d rear axle, whi ch dri ves bot h rear wheel s equal ly at all times. This mea ns that the wheel on the outside of the turn m us t trav el a greater di st ance t han t he i ns id e wheel when tur ning and the inside tire must slip tr ac tion slightly . T o turn, steer in [...]

54 OPERATION Driving Safely Driving on Slippery S urfaces When ever riding on slipper y surfaces s uch as wet t rail s or loose grave l, or during freezing weather , fol l ow th ese precaut i ons : 1. Slow down when enteri ng s li pp ery areas. 2. Engage A WD before whe els be gin to lose trac tion. 3. Mainta in a high lev el of alert nes s, readi [...]

55 OPERATION Driving Safely T raveling Uphill Whe neve r tra veling uphill, follow these pr ecauti ons : 1. Always trave l straight uphill. 2. A void steep hills (25 _ ma ximum). 3. Keep both f ee t on the footre sts. 4. T ransfer your weight for ward. 5. P ro ceed at a st eady rat e of speed an d th ro ttle opening. 6. Remain a lert a nd be pre pa[...]

56 OPERATION Driving Safely Sidehilling W ARNING Impr operly crossing hills or tur ning on hills can r esult in loss of contr ol or v ehicle over tur n, r esult ing in sever e injury or death. Avoid cross ing the s ide of a hill when pos sible. Follow proper procedur es as out lined in the owner ’s manual. Sidehilling can be the most dange rous t[...]

57 OPERATION Driving Safely T raveling Downhill W ARNING Exces sive s peed when tr aveling downhill can c ause loss of contr ol and serious injury or deat h. Whe n trav eling downhill, follow these pr ecaut io ns: 1. T ransfer your we ight to the rear . 2. Drive str aight down the hill. 3. S l ow d own . S queeze t he b rake l ever gradually . W AR[...]

58 OPERATION Driving Safely T urni ng Ar ound on a H ill W ARNING Im proper hill c limbing proc edures c ould cause los s of control or overt urn and r esult in s erious injury or deat h. Avoid climbing st eep hills ( 25 _ maximum). Use ext reme c aution when oper ating on hills , and f ollow proper operat ing procedur es outlined in t he owner ’[...]

1 59 OPERATION Driving Safely Dr ivi ng Through W ater Y our A TV can ope rate through wate r with a maximum rec omme nded depth equa l to the bottom of the footre sts (1). Follow thes e pro cedures when opera ting through wate r: 1. Deter mine wate r depths and current before crossing. 2. Choose a crossing where both banks have gradua l inclines. [...]

60 OPERATION Driving Safely Driving Over Obstacles Be alert ! Look ah ead and l earn to read t he terrai n yo u’re trav eli ng o n. Be con st ant ly al ert for h azards su ch as l ogs , ro cks an d low h angi ng branch es. W ARNING Severe injur y or death can res ult if your v ehicle com es in cont act with a hidden obst acle. Not all obst acles [...]

61 OPERATION Driving Safely Driving in Rever se Fo ll ow th ese precau ti ons when op erati ng i n reverse: 1. Always avoid back ing downhill. 2. Back slowly . 3. Wh en in rev erse, apply the brake s lightly for stopping. 4. A void turning at sharp an gl es in reverse. 5. Never open the throttle sudde nly while bac king. W ARNING Failur e to use c [...]

62 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on an inc line if possible . If it’ s unavoidable, follow thes e precau ti on s: 1. T urn the engine off . 2. Place the tra nsmission in park. 3. Set the parking brake. 4. Always block the rear whe els on the downhill side as shown.[...]

63 EMISSION C ONT RO L SYST EMS Noise Em ission C ontrol System Do not modify the engine, intake o r exhaust components, as doing so may af fect complia nce w ith state and loca l noise level requir eme nts. Spar k Ar restor Y our Polaris vehic le ha s a spa rk ar re stor that w as teste d and qua lifie d to be i n accordance wi th t he US DA F ore[...]

64 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V power f or opera ting accesso ries such as ha nd held spot lights. See your Pola ris dea ler . Per iodic Maintenance Char t Care ful periodic ma intenan ce will help keep your vehic le in the safest, most relia ble c ondition. Inspection, adjustme nt and lubric ation o[...]

65 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all s ervices at wh ich ever main ten ance int erval i s reached firs t. Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Steering -- P re-R ide -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us pe[...]

66 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) " Transmis s ion oil 25 H Monthly 250 ( 400) Inspec t lev el; c hange year ly " E Engine breather filter (if equipped) 25 H Monthly 250 ( 400) Inspec t; c lean if needed " Gener al lub[...]

67 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J E Spark plug 100 H 12 M 1000 (1600) I nspec t; replac e as needed J E Ignition Timing 100 H 12 M 1000 ( 1600) Ins pect " Wiring 100 H 12 M 1000 (1600) Ins pec t for w ear , routing, sec urit y[...]

68 MAINTENANCE AND LUBRICATION Per iodic Maintenance Recor d Use th e fol lo wing chart t o reco rd peri od ic m ain tenan ce. Maintenance In terval Perfo rmed Ser v icing Date Ser vic ing Dealer or Pe rs on Remarks[...]

69 MAINTENANCE AND LUBRICATION Lubri cation Guide Chec k and lubric ate all compone nts at the inte rva ls outlined in the Periodic Mainte nanc e Chart beginning on page 64. Items not listed i n the char t should be lubricated at the Ge nera l Lubrica tion interval. Lubri cati on Guide Ke y " More of ten under seve re use , such as we t or dus[...]

70 MAINTENANCE AND LUBRICATION Pr em ium 4 S ynthetic Lubr icant Polaris Pre mium 4 All Season synthetic engine oil ha s bee n specia lly formula ted for use in Polar is 4-cyc le engine s. It’ s a fully synthetic, high perf orma nce , multi-viscosity oil de signed to provide the ultimate in l ub ricat io n p erforman ce and protect io n. S ee pag[...]

71 MAINTENANCE AND LUBRICATION Oil Level The oil dipstick a nd fill tube ( 1) is loca ted on the e ngine a nd is accessi bl e on the l eft s id e of t he A T V . 1. Position the A TV on a level surf ace. 2. Start the engine and let it idle for 20-30 sec onds, then stop the engine. 3. L ift the l ever l ock (2 ) to remov e the dipstick. W ipe it dry[...]

72 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION Hot oil c an cause ser ious bur ns to s kin. Do not allow hot oil t o come int o cont act with sk in. Alwa ys change the oil and filte r at the interv als outlined in the Periodic Maintena nce Char t beginning on page 64. Always cha nge the oil filter whenev er chang in g oi l. 1. Positio[...]

73 MAINTENANCE AND LUBRICATION T r ansm ission Oil Always che ck and c hange the tran smission oil at the interva ls outlined in t he P eri od ic M ain ten ance C hart beginning on page 64. Maintain the tran smission oil leve l at the bottom of the fill plug hole (1). W e rec ommend the use of Polaris Pre mium AGL Sy nt het ic Gearcas e Lub rican t[...]

74 MAINTENANCE AND LUBRICATION Front Gear case Oil Always check an d chan ge t he fron t g earcase oi l at th e in terval s outlined in the Periodic Mainte nanc e Chart beginning on page 66. Mainta in the oil level even with the bottom of the fill hole threads (1). W e recomme nd the use of Polaris Premium De mand Dr ive Hub Fluid. Use of other oil[...]

2 1 3 75 MAINTENANCE AND LUBRICATION Rear Gear case Oil The rear g earcase fi ll plu g (1 ) is lo cated o n t he rear o f th e gearcase. Always ch eck and chang e th e rear gearcas e oi l at the inter vals outline d in the Peri od ic M ain ten ance C hart beginning on page 64. Mai nt ain the rear g earcase oil level ( 2) eve n with the bottom of th[...]

76 MAINTENANCE AND LUBRICATION Engine Cooli ng System Radiator Coolant Level T o ensure that the coola nt maintains its ability to protect the engine, we recomm end t hat t he sy st em be com pl etel y drai ned ev ery two years and a fresh m i xtu re of an ti freeze and water add ed. P ol aris recomm end s t he use o f P olari s Prem ium 60/ 40 ant[...]

77 MAINTENANCE AND LUBRICATION Engine Cooli ng System Coolant Level The r ecove ry bottle (1) is loca ted on the left sid e of t he m achi ne. T o acces s t he rec over y bottle, remove the left side pane l as outlined on pa ge 81. Mainta in the coola nt leve l betwe en the minimum and maximum mar ks on the bottle (whe n the fluid is cool). Add coo[...]

78 MAINTENANCE AND LUBRICATION Br akes The front and re ar bra kes are hydr aulic disc br akes, activa ted by moving the single brake leve r toward the handle bar . These br akes ar e self- adjusting. The fo ll owi ng ch ecks are recomm ended to keep the b rake sy st em i n good opera ting condition. Check mor e ofte n if bra kes a re use d hea vil[...]

79 MAINTENANCE AND LUBRICATION Br akes 2. C heck the b rake s yst em for flu id leaks . 3. C heck the b rakes for exces si ve t ravel or spongy fee l. 4. C heck t he frict i on pad s for wear , damage a nd looseness. 5. C heck t he secu rit y and s urface condition of the disc. NOT E: Replace br ake pads when t hey a r ew o r nt o3 / 6 4 ″ (.1 cm[...]

80 MAINTENANCE AND LUBRICATION T oe Ali gnment W ARNING Sever e injury or death can res ult f rom improper t oe alignment and adjustm ent. Do not att empt to adjus t t ie rod alignment . All t ie rod adjustm ents should be perf ormed by an authoriz ed Polaris dealer . Use the following proce dure to chec k the toe alignment of the vehicle. The rec [...]

81 MAINTENANCE AND LUBRICATION Side P anel R emoval 1. Remove the sea t. 2. Gras p t he rear o f th e si de p anel n ear t he rear cab. W i t h a fi rm motion, pull the pane l outward to disengage the side pane l from the grommet. 3. Pull the panel downwar d and r ear ward to r emove it f rom the A TV . 4. Reinstall the side panel by rever sing the[...]

82 MAINTENANCE AND LUBRICATION W ARNING Operat ing your A TV with worn t ires , im properly inflated t ires , non-st andard tir es or impr operly inst alled tires will affec t vehic le handling and could caus e an accident result ing in serious injury or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your A TV and in the ow[...]

83 MAINTENANCE AND LUBRICATION Wheel Installation W ARNING Im properly installed wheels c an advers ely affec t t ire wear and vehicle handling, which can res ult in s erious injur y or deat h. Always ens ure t hat all nut s ar e tor qued to s pecif icat ion. Do not serv ice axle nut s t hat hav e a cot ter pin installed. S ee your Polaris dealer. [...]

84 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. R em ove t he s eat , r eleas e th e air box cover clips, and re move the air box cover . 2. Loosen the c lamp a nd re move the filte r . 3. Remove the fa bric type pre -f ilter (1) f rom the main filte r (2) . W ash the pre -f ilter in soa py wa ter , then rinse and let dry . 4. [...]

85 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a ha logen lamp, don’ t touch the la mp with bar e finger s. Oil fr om your skin le ave s a r esidue , causing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driv ing can result in sever e injury or death. Headlight and t aillight lens es becom e dirt y duri[...]

86 MAINTENANCE AND LUBRICATION Lights High Beam Adju stmen t The h eadl ig ht beam can be adj ust ed slightly upward or downwar d. Use the following proce dure to make the adjustment. 1. Position the vehicle on a leve l surfac e with the hea dlight approxima tely 25 f t. (7.6 m) from a wall. 2. Measur e the distanc e from the floor to the cente r o[...]

87 MAINTENANCE AND LUBRICATION Lights Headlight Housin g Replacement 1. Remove the two screws on the lower front corner s of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rea r of the pod. 3. Lift the pod cover and disconne ct the speedome ter harn esses fr om th e speed om eter . 4. Unplug the hea dlamp f rom the wir[...]

1 1 2 2 1 88 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Rem oval / Installation 1. T urn the back of the headlight harne ss (1) counter clockwise and pull the harness asse mbly away from the h eadl igh t asse mbly . 2. Remove the he adla mp and install the new hea dlamp. 3. Reinstall the harne ss assembly into the headlight asse mbly . 4. T [...]

89 MAINTENANCE AND LUBRICATION Spar k Pl ugs S Use RC 7YC spark plugs . S Proper ele ctrode gap is .035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-r ecomm ended spark plugs can result in serious engine damage. Alway s use P olaris- recom mended spar k plugs. Spark plug c ondition is indicative of engine opera tion. [...]

90 MAINTENANCE AND LUBRICATION V ehi cl e Imme rsi o n CAUTION If your vehic le becomes immers ed, m ajor engine damage c an result if t he machine is not t horoughly ins pect ed. T ak e the vehicle t o your dealer before s tar ting t he engine. If it’ s impossible to t ake your A TV to a dealer be fore sta rting it, follow the steps outlined bel[...]

1 2 91 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following war nings while ser vicing t he spar k arres tor could r esult in s erious injur y or deat h. Do no t perform service on the sp ark arrestor whi le the system is hot. Exhaust syst em tem perat ures ca n reach 1000 ° F . Allow component s t o cool s ufficie[...]

92 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of the Polaris PVT system is depe ndent on engine speed and veh icl e to rqu e requi remen ts . As engi ne s peed increas es, the forc e exer ted on the movable drive sheav e by the flyweights also incre ase s. This, in tur n, incre ase s the amount of pinch a p p l i e dt ot h e drive[...]

93 MAINTENANCE AND LUBRICATION PV T System W ARNING Failure t o com ply wit h the ins tr uct ions in t his warning can r esult in sever e injury or death. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength so t hat a failure m ay occ ur at a high speed. The PVT system has been precisio n balanced. Any modificat ion[...]

94 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connecting or disconnect ing bat ter y cables can result in an explosion and c ause ser ious injury or death. W hen remov ing the bat ter y , always disc onnect the negat ive (blac k) cable fir st . When r einst alling the bat t ery , always connec t t he negative ( black) cable last . Ba[...]

95 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe neve r the vehicle is not used for a per iod of three months or more, remov e th e bat tery from t he veh icl e, ensu re that it ’ s fu ll y ch arged, an d st ore it o ut o f the su n in a coo l, dry pl ace. C heck b att ery vol t age each mo nth d uri ng s to rage and rech arge as nee[...]

96 MAINTENANCE AND LUBRICATION Batter y Batt ery Charg ing NOT E: Alway s ver ify batt ery c ondition bef ore and 1- 2 hours af t er t he end of c harging. Stat e of Charge Vo l t a g e Acti on Char ge T ime* (Us ing cons tant cur rent char ger @ s tandard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. f r om dat e [...]

97 MAINTENANCE AND LUBRICATION Cleaning and S tor age See page 107 for the par t numbers of Polaris products. Cleaning the A T V Keep ing your A TV clea n will not only improve its appe ar ance but it ca n also exte nd the lif e of v arious c omponents. W ith a few precautions , your A TV can be cleaned much l ike an automobi le. W ashin g the A TV[...]

98 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s CAUTION Star ting t he engine during t he st orage per iod will dist urb t he prot ecti ve film c reat ed by f ogging and damage could oc cur . Nev er star t t he engine during t he st orage per iod. Clean t he Exter ior Make ne ce ssar y repa irs a nd then cle an the A TV thorou[...]

99 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s Fog the Engi ne 1. T reat the f uel syste m with Polar is Carbon Cle an, following the instructions on the ca n. R un the engine for seve ra l minutes so the Carb on C l ean reaches the i nj ecto rs. Turn the en gi ne off. 2. Remove the spark plugs a nd add 2-3 ta blespoons of Pr[...]

100 MAINTENANCE AND LUBRICATION Cleaning and S tor age Chr om e Whee l Car e (if e quipped) Pro per mai nten ance wil l prot ect chro me wheel s from corros io n, preserv e wheel life an d ens ure a “l ik e new” app earance for many y ears. 1. W ash chrome r ims freque ntly . Use a mild deter gent to remove any salt, dirt, mud or grime . Never [...]

101 ADJUSTMENTS Cam ber and C aster The cambe r and ca ster ar e non-a djustable . Rear S pring The rea r shock absor ber spring is adjuste d by rota ting the adjuste r ( 1) eit her cl ock wis e or counter clockwise to incre ase or decrease s pri ng tens io n. NOT E: Accessory sprin gs are available thr ough your Polaris dealer. Handlebar s W ARNIN[...]

102 ADJUSTMENTS Throttl e Body/Idl e RP M Idle RPM is preset by the manufac turer . If the engine idle spee d is not satisfa ctor y , plea se see your Polar is deale r for adjustme nt. Throttl e Cable Fr eeplay Throttle c able f re epla y is adjusted at the handleba r . 1. Slide the boots (1) off the inline ca ble adjuste r slee ve (2). Loosen the [...]

103 TROUBLE S HOOTIN G Drive Belt and Cover Pr oblems Po ssib le Cau se Soluti on Dri vi ng t he A TV ont o a pick u p o r tall trailer in high r a nge Shif t tr a ns mis sion t o l ow ra nge duri ng l oadi ng of the A TV to pre ve nt be lt bur ni ng. Sta r ti ng out going up a steep inclin e Whe n s ta r t ing out on a n inc l i ne, us e low r a n[...]

104 TROUBLE S HOOTIN G Contact your Polaris dea ler for se rvice if you’ re unable to identif y solutions using the following c har ts. Engine Doesn’t T urn Over Possi bl e Cause Sol utio n Tripp ed circuit b reak er Reset th e b reak er Lo w b attery v o ltage Rec ha r ge ba tt e ry t o 12. 8 VDC Loose ba t t er y conne c ti ons Ch eck all con[...]

105 TROUBLE S HOOTIN G Engine Backfires Possi bl e Cause Sol utio n W ea k spa rk fr om s pa rk pl ugs In spect, clean an d/o r replace spark p lu g s Inco rrect spark p lu g g ap o r heat rang e Set ga p t o spe cs or r epl a c e plugs Old or non- r ec omm e nded f ue l Repl a c e wit h new fue l Inco rrectly in stalled sp ark plu g w ires See you[...]

106 TROUBLE S HOOTIN G Engi ne Stops or Loses P ower Possi bl e Cause Sol utio n Out of fuel Refu el, cycle key to ON p ositio n th ree ti me s f or 5 sec onds each , th en start Kinke d or plugge d fuel ve nt line Insp ect an d r eplace W ater p resent in fu el Repl a c e wit h new fue l Foule d or de fe c t ive s pa rk pl ugs Insp ect, clean and [...]

107 POLARIS PRODUCTS Part No. Descri pt ion Engine Lubr icant 2870791 Fogging Oi l ( 12 oz. Aerosol) 2871281 Premi um 4 Synt heti c 0W - 40 (4- Cycl e) Engi ne Oi l ( qt. ) 2871844 Premi um 4 Synt heti c 0W - 40 (4- Cycl e) Engi ne Oi l ( gal. ) Gearcase / T ransmi ssion Lubri cant s 2873602 Premi um AG L Synthet ic Gear case Lube ( qt. ) 2873603 P[...]

108 SPECIFICA TIO NS SPORT SMAN 80 0 EF I Gro ss V ehicle W eight 1240 lbs . (563 kg) Fu el C apacity 4. 13 ga l. ( 15.6 l ) Engine Oi l Ca pa c it y 2q t s .( 1 . 9l ) Rear G earcase O il Cap acity 10 oz. ( 300 ml ) Fro n t Gearcase O il C apacity 5 oz . ( 150 ml ) Transm issio n O il C ap acity 15 oz. ( 450 ml ) Co o lan t Cap acity 3 . 2q t s .([...]

109 SPECIFICA TIO NS SPORT SMAN 8 00 EF I Transm issio n Au to matic E BS w /E -Z S h ift H/L /N /R/P Gear R edu ctio n (L o w ) 7.49: 1 Gea r Re duc ti on (Re ver s e) 5.11: 1 Ge ar Re duc t ion (Hi gh) 2.70: 1 Driv e Ratio (Fro n t) 3.82:1 Driv e Ratio (Fin al) 3.10: 1 Tires / Pressu re (F ro nt ) P o l a r i sP X T2 6x8-1 2/ 5p s i Tires / Press[...]

11 0 WARRANTY LIM ITED W ARRANT Y Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, give s a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehicl e (A T V) again st defects in m ateri al o r work man shi p. Polaris also give s a one year limited wa rr anty on the final drive ch ain for fa ilure due to defe cts. Thi[...]

111 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIM IT A TIONS OF W ARRANTIES AND REM EDIES The Polar is limited wa rr anty e xcludes a ny fa ilure s that are not cau sed by a def ec t in mater ial or workma nship. This warranty doe s not cover accid ental dam age, norm al w ear and t ear , abu se o r im prop er han dl in g. This warr anty also d[...]

11 2 WARRANTY ALL IMPLIED W AR RANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W AR RANTIES OF MER CHANT ABILITY AND FITNES S F OR A P AR TIC ULAR P URP OSE) AR E LIMITED IN DURA TION TO THE ABOVE S IX MONTH W AR RANTY P ERIOD. POLARIS F UR THER DIS CLAIMS ALL EXPR ESS W AR RANTIES NOT ST A TED IN THIS W AR RANTY . S ome s tates do not all ow lim[...]

11 3 WARRANTY Exported V eh icles EXCE PT WH ERE SPE CIFI CAL L Y REQU IRE D BY LA W , THERE IS NO W AR RANTY OR SER VIC E BULLETIN C OVERAGE ON THIS VEHICL E IF IT IS S OLD OUTSIDE THE C OUNTR Y OF THE SELLING DEALER ’S AUTHOR IZED LOCA TION. Thi s po li cy do es no t app ly t o veh icl es th at hav e receiv ed aut hori zat io n for e xport f ro[...]

11 4 WARRANTY Exported V eh icles How to Ge t Se rv ic e If Purchased From A Private Party : If you purcha se a Polaris product fr om a private citiz en outside of the country in whic h the vehic le wa s origina lly purcha sed, all wa rra nty cover age will be denied. Notic e If your vehic le is registere d outside of the country where it was pur- [...]

11 5 INDEX A Accesso ries 6 4 ................... ADJ USTMENTS 101- 102 .......... Ag e R estriction s 11 ............... Air F ilter S ervi ce 84 ............... All Whe el Dr ive 39 ............... Au to matic Tran smissio n 38 ......... Au x iliary Brak e 7 9 ............... AW D 3 9 ........................ B Bat t er y 94- 96 .................[...]

11 6 INDEX N Nois e Emi s s ion Contr ol Sys te m 63 ... O Odome t er 42 .................... Oil C hange 72 ................... Oil F ilter Ch an g e 72 .............. Oil L ev el 71 ..................... OPERA TION 46-62 ............... Op erato r S afety 11-3 1 .............. Ov errid e Sw itch 3 2 ............... P Park in g Brak e 36 .........[...]