Мануал поларис спортсмен 800

Chapters

Troubleshooting

• Page 1
  PMS 419 Sportsman 800 EFI Owner’s Manual for Maintenance and Safety 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.
• Page 2
  WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800- 342-3764 for assistance.
• Page 3
  The text is printed on 100% recycled with 40% post-consumer waste (PCW).
• Page 4
  PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER CARRY NEVER USE NEVER USE ALWAYS USE PASSENGERS ON PUBLIC WITH DRUGS AN APPROVED HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions.
• Page 5
  WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ® •…
• Page 6
  The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2011 SPORTSMAN 800 EFI Owner’s Manual P/N 9922805…

• Page 7: Table Of Contents

  TABLE OF CONTENTS Introduction ……4 Safety ……. . . 7 Features and Controls .

• Page 8: Introduction

  INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

• Page 9
  INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

• Page 10: Vehicle Identification Numbers

  INTRODUCTION Vehicle Identification Numbers Record your vehicle’s identification numbers and key number 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 POLARIS key blank (using your key number) and mating it with one of your existing keys.

• Page 11: Safety

  SAFETY Safety Training ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCourse that is available to you and your eligible family members.

• Page 12: Safe Riding Gear

  SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards.

• Page 13: Eye Protection

  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 shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

• Page 14: Operating Without Instruction

  SAFETY WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

• Page 15: Safety Warnings

  SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • 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- eling is performed or where gasoline is stored.

• Page 16: Protective Apparel

  SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious 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).

• Page 17: Operating On Pavement

  SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.

• Page 18: Physical Control Of The Atv

  SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could also contact the rear wheels.

• Page 19: Descending Hills Improperly

  SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for travel- ing down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling down- hill.

• Page 20: Stalling While Climbing A Hill

  SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. •…

• Page 21: Operating On Slippery Terrain

  SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating 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.

• Page 22: Improper Tire Maintenance

  SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision 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 ATV.

• Page 23: Skidding Or Sliding

  SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual.

• Page 24: Improper Cargo Loading

  SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV 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 ATV. • Cargo should be properly distributed and securely attached. •…

• Page 25: Operating A Damaged Atv

  SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.

• Page 26
  SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
• Page 27
  SAFETY Safety Labels and Locations General Warning Discretionary Warning   Tire Pressure/Load Warning Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. 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) •…

• Page 28: Age 16 Warning

  SAFETY Safety Labels and Locations “No Passenger” Age 16 Warning Warning Rack Rack Warning Warning      Clutch Cover Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

• Page 29: Clutch Cover Warning

  SAFETY Safety Labels and Locations Clutch Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

• Page 30: Features And Controls

  FEATURES AND CONTROLS Switches Headlight Switch Switch Main Key Switch Mode/Reverse Override Engine Switch Stop Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, release the throttle and depress the override button.

• Page 31: Engine Stop Switch

  FEATURES 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 off all electri- cal power to the vehicle, including lights.

• Page 32: Throttle Lever

  FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.

• Page 33: Brake Lever

  FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.

• Page 34
  FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder 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 brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

• Page 35: Parking Brake

  FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 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.

• Page 36
  FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
• Page 37
  FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the Selector vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a com- plete stop.

• Page 38: Engaging Awd

  FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two- wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will…

• Page 39: Instrument Cluster

  FEATURES AND CONTROLS Instrument Cluster Your ATV 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.

• Page 40: Rider Information Center

  FEATURES 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 may have shut off to protect the electronic speedome- ter.

• Page 41
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV.
• Page 42
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
• Page 43
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the all- wheel-drive coil.
• Page 44
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle 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, depending on your preference.
• Page 45
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. See page 43 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
• Page 46
  FEATURES 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 (injector, 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 the chart.
• Page 47
  FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery…

• Page 48: Operation

  OPERATION WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

• Page 49
  OPERATION 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 70. Add oil if necessary to maintain the level between the safe and add marks. 3.

• Page 50: Pre-Ride Checklist

  OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it’s in safe operating condition. Item Remarks Page Brake system/lever travel…

• Page 51: Safe Operation Practices

  OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.

• Page 52: Trail Etiquette

  OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club or local officials.

• Page 53: Starting The Engine

  OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.

• Page 54: Driving Procedures

  OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

• Page 55: Turning The Vehicle

  OPERATION Turning the Vehicle Your ATV 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.

• Page 56: Driving On Slippery Surfaces

  OPERATION Driving on Slippery Surfaces Sideways Turn in direction skid of skid 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 rough, slippery or loose terrain. 2.

• Page 57: Driving Uphill

  OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25 maximum). 3.

• Page 58
  OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

• Page 59: Driving Downhill

  OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25 maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of con- trol.

• Page 60
  OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

• Page 61: Driving Through Water

  OPERATION Driving Through Water Your ATV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these procedures when operat- ing through water: 1. Determine water depths and current before entering water.

• Page 62: Driving Over Obstacles

  OPERATION Driving Over Obstacles Follow these precautions when 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.

• Page 63: Driving In Reverse

  OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.

• Page 64: Hauling Cargo

  OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

• Page 65: Towing Loads

  OPERATION Hauling Cargo Never exceed the weight capaci- ties specified for your ATV on warning labels and 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 possible.

• Page 66: Parking On An Incline

  OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

• Page 67: Emission Control Systems

  EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrestor that was tested and quali- fied to be in accordance with the USFS standard 5100-1c.

• Page 68: Maintenance

  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 maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer.

• Page 69: Periodic Maintenance Chart

  MAINTENANCE Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key …

• Page 70
  MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km)  Steering Pre-Ride Make adjustments as need ed. See Pre-Ride Checklist  Front suspension Pre-Ride on page 46.
• Page 71
  MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km)  General 50 H 500 (800) Lubricate all fittings, pivots, lubrication cables, etc.  Throttle Cable/ 50 H 500 (800) Inspect; adjust; lubricate; ETC Switch replace if necessary E Throttle Body 50 H…
• Page 72
  MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km)  Clutches (drive 100 H 12 M 1000 (1600) Inspect; clean; replace worn and driven) parts  Front wheel 100 H 12 M 1000 (1600) Inspect; replace as needed bearings …

• Page 73: Lubrication Guide

  MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 64. 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 needed.

• Page 74: Engine Oil

  MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil.

• Page 75: Oil And Filter Change

  MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.

• Page 76
  MAINTENANCE Engine Oil Oil and Filter Change 11. Lubricate the o-ring on the new filter 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.

• Page 77: Transmission Oil

  MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the oil level at the bottom of the fill plug hole threads. See page 118 for the part numbers of POLARIS products.

• Page 78: Oil Change

  MAINTENANCE Transmission Oil Oil Check 1. Position the vehicle on a level surface. Fill Level 2. Remove the footwell. Remove the fill plug. Check the oil level. 3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.

• Page 79: Fluid Change

  MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 64. We rec- ommend the use of Demand Drive Plus Fluid. Use of other fluids may result in improper operation of components.

• Page 80: Cooling System

  MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle.

• Page 81: Radiator Coolant

  MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains 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 cooling system has been drained for maintenance or repair.

• Page 82: Hand Brake

  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 diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.

• Page 83: Toe Alignment

  MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.

• Page 84: Camber And Caster

  MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted Adjuster by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer.

• Page 85: Throttle Cable Freeplay

  MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. 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.

• Page 86: Side Panel Removal

  MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2.

• Page 87: Wheel Removal

  MAINTENANCE Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

• Page 88: Wheel Installation

  MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 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 toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5.

• Page 89: Air Filter

  MAINTENANCE Air Filter 1. Remove the seat. Pre-Filter 2. Release the air box cover clips, and remove the air box cover. Main Filter 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

• Page 90: Fuse Replacement

  MAINTENANCE Fuse Replacement Fuse Feature Supported Speedometer Electronic Fuel Injection (Main Fuse) Ignition, Lighting Accessories, 12V Power Receptacle 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.

• Page 91: Headlight Lamp Replacement

  MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, don’t touch the lamp with bare fingers.

• Page 92: High Beam Adjustment

  MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2″ (5 cm) 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft.

• Page 93
  MAINTENANCE Lights Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or down- ward. 3. Tighten the screw.

• Page 94: Headlight Housing Replacement

  MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower 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 disconnect the speedometer harnesses from the speedometer.

• Page 95: Lower Headlamp Replacement

  MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. Harness 4.

• Page 96: Spark Plugs

  MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 116 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.

• Page 97
  MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan 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 white.

• Page 98: Vehicle Immersion

  MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

• Page 99: Spark Arrestor

  MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

• Page 100: Pvt System

  MAINTENANCE PVT System WARNING 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 high speed. The PVT system has been precision balanced.

• Page 101
  MAINTENANCE PVT System 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 turn, increases the amount of pinch applied to the drive belt.

• Page 102: Pvt Drying

  MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) High PVT Drying There may be some instances when water is accidently ingested into the…

• Page 103: Battery Maintenance

  MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion 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. WARNING Battery electrolyte is poisonous.

• Page 104: Battery Removal

  MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover (if equipped). 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6.

• Page 105: Battery Installation

  MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 103 before installing the battery.

• Page 106: Battery Storage

  MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

• Page 107
  MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 100. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
• Page 108
  MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

• Page 109: Cleaning And Storage

  MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear- ance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.

• Page 110: Polishing The Vehicle

  MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow- ing items: •…

• Page 111
  MAINTENANCE Cleaning and Storage 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.

• Page 112: Storage Tips

  MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended. See page 105.

• Page 113
  MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 64. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) •…
• Page 114
  MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 64. Battery Maintenance Remove the battery and recharge it as outlined on page 103. Store the battery in a cool, dry place.

• Page 115: Transporting The Vehicle

  MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.

• Page 116: Troubleshooting

  TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range or turn around using the K-turn (see page steep incline 56).

• Page 117
  TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker or blown fuse Reset the breaker/Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause Solution…
• Page 118
  TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs…

• Page 119: Engine Overheating

  TROUBLESHOOTING Engine Stops or Loses Power 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 Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug…

• Page 120: Specifications

  SPECIFICATIONS SPORTSMAN 800 EFI Maximum Weight Capacity 480 lbs. (218 kg) Dry Weight 741 lbs. (336 kg) (with cast wheels) 751 lbs. (341 kg) (with steel wheels) Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts.

• Page 121
  SPECIFICATIONS SPORTSMAN 800 EFI Transmission Automatic PVT with 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 Tires/Pressure, Front 26×8-12 / 5 psi (34.5 KPa) Tires/Pressure, Rear 26×11-12 / 5 psi (34.5 KPa)

• Page 122: Polaris Products

  POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2878068 AGL PLUS Transmission Fluid (qt./.95 l) 2878069 AGL PLUS Transmission Fluid (gal./3.8 l) 2877922…

• Page 123: Declaration Of Conformity

  2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 We, POLARIS Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS…

• Page 124: Warranty

  WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS All Terrain Vehicle (ATV) against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects.

• Page 125
  WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • Wheels and tires •…
• Page 126
  WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at POLARIS’ exclusive option, repair or replacement of any defective materials, or components or products.
• Page 127
  Vehicles importa- tion rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country.
• Page 128
  WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
• Page 129
  This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
• Page 130
  WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.

• Page 131: Maintenance Log

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

• Page 132
  MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS…
• Page 133
  MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS…

• Page 134: Index

  INDEX Accessories ….110 Demand Drive Capacities ..75 Air Filter ….. 85 Demand Drive Fluid .

• Page 135
  INDEX Gasoline Handling ….11 Gear Selector….33 Demand Drive ….75 Engine .
• Page 136
  INDEX Starting the Engine … . . 49 Vehicle Identification Numbers..6 Steering Assembly ….82 Vehicle Immersion .

инструкцияPolaris Sportsman 800 EFI (2013)

Owner’s Manual

for Maintenance and Safety

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.

Sportsman Forest 800

Посмотреть инструкция для Polaris Sportsman 800 EFI (2013) бесплатно. Руководство относится к категории Без категории, 1 человек(а) дали ему среднюю оценку 8.3. Руководство доступно на следующих языках: английский. У вас есть вопрос о Polaris Sportsman 800 EFI (2013) или вам нужна помощь? Задайте свой вопрос здесь

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