Polaris 800 Big Boss - Manuals

4 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...

6 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 o...

7 SAFETY Safety Training Safety training is a top priority for Polaris. When you purchased your new vehicle, your dealer instructed you on the authorized ATV Rider- Course sm available to you and your eligible family members. This train- ing is included in the purchase price of your vehicle. Polaris...

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. Wear pro-tective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds estab...

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 shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markin...

10 SAFETY Failure to operate the vehicle 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 operati...

11 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 spa...

12 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...

13 SAFETY Safety Warnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn.Avoid operating the vehicle on pavement. The...

14 SAFETY Safety Warnings Physical Control of the Vehicle 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 vehicle. If the operator's foot is not firmly planted on the footres...

15 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. Se...

16 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. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a h...

17 SAFETY Safety Warnings Operating on Steep Hills Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the vehicle or for your abilities. Never operate the vehicle on hills steeper than 25 degrees. Operating on Slippery Terrain Failure to use extra caut...

18 SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the o...

19 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle 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 vehicle. • Cargo should be properly distributed and securely a...

20 SAFETY Safety Warnings Operating Through Deep Water Operating the vehicle through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn.Avoid operating the vehicle through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the reco...

21 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle 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 ...

22 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructi...

23 SAFETY Safety Labels and Locations Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.• Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa)Rear: 10.0 psi (68.9 kPa) • Maximum...

24 SAFETY Safety Labels and Locations Container/No Passenger Warning WARNINGRemove flammable containers from box before refueling.WARNING• Passengers can be thrown off. This can cause serious injury or death.• Never carry passengers.Maximum Box Load 800 lbs. (363 kg) 7079316 + Clutch Cover Warning +...

25 SAFETY Safety Labels and Locations Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER operate this ATV if you are under age 16. 7172588 Clutch Cover Warning WARNING• Moving parts hazard under belt-clutch guard. To prevent ...

26 FEATURES AND CONTROLS Switches 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. WARNING! Pressing the override button while the throttle is open can cause l...

27 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, ...

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

29 FEATURES AND CONTROLS Brake Systems Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the rear brake. Do not aggressively apply the rear brake when going forward. T...

30 FEATURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti-vated disc brakes. Always test brake lever travel and master cylinder fluid level before riding. When s...

31 FEATURES AND CONTROLS Master Cylinder/Brake Fluid 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, ...

32 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. Release the brake lever. 5. To release the parking brake...

33 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE...

34 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the 4X4 (AWD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline. Always move the 4X4 sw...

35 FEATURES AND CONTROLS All Wheel Drive System Engaging AWD The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable AWD until the engine RPM is below 3100. Once enabled, AWD remains enabled until the 4X4 switch is turned off. If...

36 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system ...

37 FEATURES AND CONTROLS Instrument Cluster Your vehicle 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 mile...

38 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 ...

39 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 reco...

40 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. T...

41 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. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing throug...

42 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...

43 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 45 for Blink Codes and Failure Descriptions. Use the follow-ing procedure to download blin...

46 OPERATION Failure to operate the vehicle 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. Break-In Period The break-in period for y...

47 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 72. Add oil if necessary to maintain the level between the safe and add ma...

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

49 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. 3. Never carry a pa...

50 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 r...

51 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 enga...

52 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. Check your surroundings and determine your path of tr...

53 OPERATION Turning the Vehicle Your vehicle 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 turn-ing and the inside tire must slip traction slightl...

54 OPERATION 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 rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before ...

55 OPERATION Driving Uphill 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. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descend...

56 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. Slow down. 2. A...

57 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. Avoid steep hills (25 ° maximum). 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Excess...

58 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. 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or desc...

59 OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Fol-low these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks h...

60 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. Travel slowly and ...

61 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. Never open the throttle sud...

62 OPERATION Hauling Cargo 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: • Never exceed the maximum weight ...

63 OPERATION Hauling Cargo 1. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety labels. The total load (operator, accessories, cargo and weight on hitch...

64 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution. ...

65 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.

66 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...

67 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 par...

68 MAINTENANCE Periodic Maintenance Chart 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 X Perform these ...

71 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at...

72 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 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. Follow the manufacturer's recommendat...

73 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 67. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to warm up ...

74 MAINTENANCE Engine Oil Oil and Filter Change 10. 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. 11. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn i...

75 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Mainte-nance Chart beginning on page 67. Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the ATV behind the footwell. The d...

76 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 67. We rec-ommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of compone...

77 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean and reinstall the drain plug. Torque to 11 ft. l...

78 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain the fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill. The fill plug is loca...

79 MAINTENANCE Middle Gearcase Oil Always check and change the mid-dle gearcase oil at the intervals outlined in the Periodic Mainte-nance Chart beginning on page 67. We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 124 for the part numbers of Polaris p...

80 MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 76 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals outl...

81 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the d...

82 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 ...

83 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 dra...

84 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. 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 l...

85 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 alignmen...

86 MAINTENANCE Steering Assembly The steering assembly of the vehicle 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. Grasp the rear of the side pan...

87 MAINTENANCE Tires Operating your vehicle 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 ma...

88 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. Lower the...

89 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. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filte...

90 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace-ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com-partment on the top...

91 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. Upper Headlight La...

92 MAINTENANCE Lights 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 surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in park. 2. ...

93 MAINTENANCE Lights 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. Tilt the headlamp upward or downward. 3. Tighten the screw. Phillips Screw

94 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. 4. Unplug the ...

95 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise 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. 4. Turn the ...

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 122 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. Always us...

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 b...

98 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 vehicle to a dealer before starting it, follow the steps outlined ...

99 MAINTENANCE Spark Arrestor 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. Do not stand behind ...

100 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 high speed. The PVT system has been precision balanced. Any modifi...

102 MAINTENANCE PVT System When To Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat-ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow th...

103 MAINTENANCE Battery 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. Ba...

104 MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 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. Lift the battery out of t...

105 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 107 before installing the battery. 1. Ensure that the batter...

106 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...

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 104. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

108 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos....

109 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance 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 h...

110 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: If an informational ...

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 suscept...

112 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 vehic...

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 67.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase• Middle gearcase...

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 67. Battery Maintenance Remove the battery and recharge it as outlined on page 107. Store the battery i...

115 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 vehicle to the transporting unit securely with su...

116 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Springs The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counterclockwise to increase or decrease spring tension. Always adjust all rear springs to equal settings. Accessory spr...

117 ADJUSTMENTS 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....

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 incline Use low range or turn around using the K-turn (see page 58). Driving at low RPM or ground speed (3-7 MPH) Drive at ...

119 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution 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 Possib...

120 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires 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 Possible Cau...

121 TROUBLESHOOTING Engine Stops 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 Water is present in fuel Replace with new fuel Fouled or defective s...

122 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman Big Boss 6X6 800 EFI Maximum Weight Capacity 1115 lbs. (507 kg) (includes operator, cargo, accessories) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Demand Drive Fluid Capacity 9.3 ...

123 SPECIFICATIONS Clutching *EBS models require no helix/spring adjustment Sportsman Big Boss 6X6 800 EFI Transmission Automatic PVT with E-Z Shift H/L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.11:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 Tir...

124 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...

125 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for fail...

126 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This ...

127 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states...

128 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-TION.This policy does not apply to vehicles that have received authorization for expo...

129 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...

131 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) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS