Polaris Sportsman 800 EFI - User Manual

Polaris Sportsman 800 EFI

Polaris Sportsman 800 EFI – User Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 3 – to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this; WARNING
  • Page 6 – WELCOME; Polaris Recreational Vehicles; RANGER
  • Page 7 – VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the
  • Page 8 – TABLE OF CONTENTS
  • Page 9 – SAFETY; Safety Decals and Locations; ATV, always read and follow the instructions of the decals
  • Page 10 – ATTENTION
  • Page 11 – NO STEP
  • Page 13 – Safe Riding Gear
  • Page 14 – Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions
  • Page 15 – The following signal words and symbols appear throughout this; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution; IMPORTANT; note
  • Page 16 – Serious injury or death can result if you do not follow these; Take a training
  • Page 18 – FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
  • Page 19 – not know how to operate the ATV properly in different situations; abilities, or judgment needed to operate an ATV safely and could
  • Page 22 – operator judgment. Reaction time may be slower and operator; control of the ATV, which can result in an accident causing severe; the chance of an accident,
  • Page 23 – schedules described in the owner’s manual.; come into contact with the rear wheels and lead to accident or
  • Page 25 – Never operate the ATV on hills steeper than 25
  • Page 26 – cause loss of control or
  • Page 28 – hills could cause loss of control or
  • Page 29 – or improperly dismounting
  • Page 30 – trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.
  • Page 33 – cargo or pulling a trailer.
  • Page 35 – FEATURES AND CONTROLS; Engine Electrical Switches; OFF
  • Page 36 – Throttle Lever; Engine speed and vehicle movement
  • Page 37 – Light Switches; ON; Brake Lever
  • Page 38 – Master Cylinder; eye
  • Page 39 – Parking Brake; Operating the ATV while the parking brake is engaged could; Setting the Parking Brake
  • Page 40 – Auxiliary Brake; Aggressively applying the auxiliary brake when backing down a; reduce; Brake Fluid Level; Fuel Tank
  • Page 41 – Automatic Transmission Gear Selector; to activate the high/park lock-out mechanism. When shifting out of; Shifting gears with the engine speed above idle or while the; Belt Life
  • Page 42 – The override switch allows activation of AWD in reverse if the; Engaging the Front Gearcase; Switching to AWD while the rear wheels are spinning may cause
  • Page 43 – Instrument Cluster; speed from the right front wheel. The instrument cluster measures; High water pressure may damage ATV components. Wash the
  • Page 44 – Rider Information Center; If the instrument cluster fails to illuminate, a battery; Engine Hour Display Indicator
  • Page 45 – mode
  • Page 46 – Diagnostic Mode; Any movement of the tires will also take the machine out of
  • Page 47 – If you scroll past the intended number, hold the button down
  • Page 48 – Special EFI Diagnostic Mode
  • Page 49 – OPERATION; Fuel Safety; Gasoline is highly flammable and explosive under certain; exhaust fumes are poisonous and can cause loss of; The engine exhaust from this product contains chemicals known
  • Page 50 – the procedures for a proper break-in. Careful treatment of a new; SH; if necessary to maintain the level between the safe and add marks.
  • Page 51 – If a proper inspection is not done before each use, severe injury
  • Page 52 – Starting the Engine; Cold Weather Operation
  • Page 53 – Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Use low forward gear when hauling or towing heavy cargo to extend
  • Page 55 – Driving Safely; Driving Procedures
  • Page 56 – Making Turns; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
  • Page 57 – Driving on Slippery Surfaces
  • Page 58 – Traveling Uphill; include quick dismounting of the vehicle.; terrain. Improper procedure could cause loss of control or
  • Page 59 – Sidehilling; control or vehicle overturn, resulting in severe injury or death.; hill while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
  • Page 60 – Traveling Downhill; Excessive speed when traveling downhill can cause loss of; Applying the brakes too firmly may cause the rear
  • Page 61 – Turning Around on a Hill; Improper hill climbing procedures could cause loss of control or; slowly
  • Page 62 – Driving Through Water; critical
  • Page 63 – Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
  • Page 64 – Driving in Reverse; apply the brakes
  • Page 65 – Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
  • Page 66 – EMISSION CONTROL SYSTEMS; Noise Emission Control System
  • Page 67 – MAINTENANCE AND LUBRICATION; Accessories; Severe Use Definition; Maintenance Chart Key
  • Page 68 – Periodic Maintenance Chart
  • Page 71 – Periodic Maintenance Record; Use the following chart to record periodic maintenance.
  • Page 72 – Lubrication Guide; Lubrication Guide Key; More often under severe use, such as wet or dusty conditions
  • Page 73 – Premium 4 Synthetic Lubricant; Mixing brands or using a non-recommended oil may cause
  • Page 74 – Oil Level; upper
  • Page 75 – Oil and Filter Change; Hot oil can cause serious burns to skin. Do not allow hot oil to
  • Page 76 – Transmission Oil; Oil Check
  • Page 77 – Front Gearcase Oil; Premium Demand Drive Hub Fluid
  • Page 78 – Rear Gearcase Oil; Use a light colored non-absorbent; Oil Change
  • Page 79 – Engine Cooling System; Radiator Coolant Level
  • Page 80 – Coolant Level; The recovery bottle (1) is located on the; Cooling System Operation; Some coolant level drop on new vehicles is normal as the
  • Page 81 – Brakes; The front and rear brakes are hydraulic disc brakes, activated by
  • Page 82 – damage and looseness.; Replace brake pads when they; main brake system. Should the main system fail, the rear brake can be; Since this is a rear brake only, it will not be as effective as
  • Page 83 – Toe Alignment; Steering Assembly
  • Page 84 – Side Panel Removal; motion, pull the panel outward to disengage the side panel from the; Footwell Removal; on the bottom of the footwell.
  • Page 85 – Operating your ATV with worn tires, improperly inflated tires,; Tire Tread Depth; Always replace tires when tread; Wheel Removal; Stop the engine, place the transmission in
  • Page 86 – Wheel Installation; Improperly installed wheels can adversely affect tire wear and; outside and rotation arrows on the tire pointing toward forward; Wheel Nut Torque Specifications; Check the wheel nut torques occasionally and when they’ve been; Nut Torque; Front Wheel Hub Tightening; component operations. All service must be performed by your
  • Page 87 – Filter Systems; Air Filter Service
  • Page 88 – Lights; When servicing a halogen lamp, don’t touch the lamp with bare; Poor lighting while driving can result in severe injury or death.; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight; Make sure the tab on the lamp locates properly in the
  • Page 89 – High Beam Adjustment; Include rider weight on the seat when measuring.; Low Beam Adjustment
  • Page 90 – Headlight Housing Replacement; The distance from the; Adjust the headlight aim by
  • Page 91 – Lower Headlamp Removal / Installation
  • Page 92 – Spark Plugs; Spark Plug Removal and Replacement
  • Page 93 – Vehicle Immersion; Check the air box for any water and dry it if it’s wet.
  • Page 94 – Spark Arrestor
  • Page 95 – PVT System; pinch; When To Use Low Range vs. High Range; Low Range
  • Page 96 – PVT Drying; the PVT system. Use the following instructions to dry it out before
  • Page 97 – Battery; in an explosion and cause serious injury or death. When; Battery Removal; initial use. Using a new battery that has not been fully charged can
  • Page 98 – Battery Storage; The following battery charging instructions apply only to the
  • Page 99 – Battery Charging; Always verify battery condition before and 1-2 hours after the
  • Page 100 – Cleaning and Storage; Cleaning the ATV; Waxing the ATV
  • Page 101 – Storage Tips; Starting the engine during the storage period will disturb the; Clean the Exterior
  • Page 102 – Fog the Engine; Do this carefully! If you miss the plug holes, oil will drain from; Inspect and Lubricate; Do not use plastic or coated materials. They do not allow
  • Page 103 – Removing Corrosion; Transporting the ATV
  • Page 104 – ADJUSTMENTS; Camber and Caster
  • Page 105 – Throttle Body/Idle RPM; satisfactory, please see your Polaris dealer for adjustment.; Throttle Cable Freeplay; freeplay is achieved at the; While adjusting freeplay, be sure to flip the throttle lever back; they touch at the midpoint of the adjuster.
  • Page 106 – TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause
  • Page 107 – solutions using the following charts.; Engine Doesn’t Turn Over
  • Page 108 – Engine Backfires
  • Page 109 – Engine Stops or Loses Power; Engine Overheating
  • Page 110 – POLARIS PRODUCTS
  • Page 111 – SPECIFICATIONS
  • Page 112 – Clutching Chart; EBS models require no helix / spring adjustment
  • Page 113 – WARRANTY; LIMITED WARRANTY
  • Page 115 – HOW TO OBTAIN WARRANTY SERVICE; Engine Oil
  • Page 116 – Exported Vehicles; How to Get Service; In the Country where your vehicle was purchased:
  • Page 117 – If Purchased From A Private Party:; Notice; chased, and you have not followed the procedure set out above, your
  • Page 118 – INDEX
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Summary

Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this; WARNING

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. The engine exhaust from this product contains chemicals known to cause cancer, birth def...

Page 6 - WELCOME; Polaris Recreational Vehicles; RANGER

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S V...

Page 7 - VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the

4 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition swi...

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