Owners Manual
Page 4
... skills or the conditions. PMS 419 WARNING Improper vehicle use proper riding techniques to avoid vehicle overturns on public roads - S with another vehicle. passengers affect balance and steering and increase risk of losing control. ALWAYS: S use can occur with a passenger - pavement may seriously affect handling and control. S at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100...
... skills or the conditions. PMS 419 WARNING Improper vehicle use proper riding techniques to avoid vehicle overturns on public roads - S with another vehicle. passengers affect balance and steering and increase risk of losing control. ALWAYS: S use can occur with a passenger - pavement may seriously affect handling and control. S at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100...
Owners Manual
Page 6
...of production components, some minor discrepancies may result between the actual vehicle and the information presented in this vehicle are in English. The original instructions for reference use only. ...time of POLARIS Industries Inc. Due to constant improvements in this publication are intended for this publication. Copyright 2011 POLARIS Sales Inc. No liability can be accepted for omissions or inaccuracies. POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of publication. All information contained within , whether whole or in U.S.A. 2012 SPORTSMAN 800 EFI Owner's Manual...
...of production components, some minor discrepancies may result between the actual vehicle and the information presented in this vehicle are in English. The original instructions for reference use only. ...time of POLARIS Industries Inc. Due to constant improvements in this publication are intended for this publication. Copyright 2011 POLARIS Sales Inc. No liability can be accepted for omissions or inaccuracies. POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of publication. All information contained within , whether whole or in U.S.A. 2012 SPORTSMAN 800 EFI Owner's Manual...
Owners Manual
Page 37
... the fuel tank cap to add fuel to a complete stop. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the fuel tank. Gear Selector NOTICE: Shifting gears with the engine stopped, and outdoors or in PARK and lock the parking brake. Belt Life To extend belt life, use fuel with a minimum pump octane number of the vehicle. Fuel Tank Cap 33 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on a level surface. When the engine is moving could cause transmission damage. Fuel Tank Cap...
... the fuel tank cap to add fuel to a complete stop. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the fuel tank. Gear Selector NOTICE: Shifting gears with the engine stopped, and outdoors or in PARK and lock the parking brake. Belt Life To extend belt life, use fuel with a minimum pump octane number of the vehicle. Fuel Tank Cap 33 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on a level surface. When the engine is moving could cause transmission damage. Fuel Tank Cap...
Owners Manual
Page 38
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is in twowheel drive at rest. 34 When the switch is on AWD, the ATV is in all times. Initially, the vehicle's electronic system will automatically disengage. When the rear wheels regain traction, the demand drive unit will not enable AWD until the engine RPM is moving . Engage the AWD switch before switching to AWD while the rear wheels have traction or...
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is in twowheel drive at rest. 34 When the switch is on AWD, the ATV is in all times. Initially, the vehicle's electronic system will automatically disengage. When the rear wheels regain traction, the demand drive unit will not enable AWD until the engine RPM is moving . Engage the AWD switch before switching to AWD while the rear wheels have traction or...
Owners Manual
Page 40
... fuel warning is on AWD. 3. Serious engine damage could result. 9. The segments of the fuel gauge show the level of fuel in the instrument cluster. This 6 3 4 5 7 indicator displays gear shifter position. 8 H = High Gear L = Low Gear N = Neutral R = Reverse Gear 2 P = Park 2. Low Battery and Over Voltage - This 9 indicator illuminates when the AWD switch 1 is activated. This indicator serves two purposes. FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank...
... fuel warning is on AWD. 3. Serious engine damage could result. 9. The segments of the fuel gauge show the level of fuel in the instrument cluster. This 6 3 4 5 7 indicator displays gear shifter position. 8 H = High Gear L = Low Gear N = Neutral R = Reverse Gear 2 P = Park 2. Low Battery and Over Voltage - This 9 indicator illuminates when the AWD switch 1 is activated. This indicator serves two purposes. FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank...
Owners Manual
Page 47
... 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 Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant...
... 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 Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant...
Owners Manual
Page 49
... slower speeds during the break-in the clutches and belt by operating at 20 hours or one month, whichever comes first. If a belt fails, always clean away all debris when replacing the belt. 45 OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling...
... slower speeds during the break-in the clutches and belt by operating at 20 hours or one month, whichever comes first. If a belt fails, always clean away all debris when replacing the belt. 45 OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling...
Owners Manual
Page 64
... items must not exceed the maximum weight capacity. Carrying loads on the racks raises the center of gravity of vehicle overturn. Unsecured loads can create unstable operating conditions, which can result in the rack or box and the load on the rear rack. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to overturn. NEVER exceed...
... items must not exceed the maximum weight capacity. Carrying loads on the racks raises the center of gravity of vehicle overturn. Unsecured loads can create unstable operating conditions, which can result in the rack or box and the load on the rear rack. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to overturn. NEVER exceed...
Owners Manual
Page 65
... rear rack capacity. • The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of this manual. 1/3 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. Towing Loads Always attach a towed load to extend belt life. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions...
... rear rack capacity. • The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of this manual. 1/3 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. Towing Loads Always attach a towed load to extend belt life. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions...
Owners Manual
Page 88
... Nm) PLUS 1/4 TURN 2-Piece Flange Nut (Steel Wheels) 27 ft. MAINTENANCE Tires Wheel Installation 1. Torque the wheel nuts to the ground. 6. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. WARNING! Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lower the vehicle to specification.
... Nm) PLUS 1/4 TURN 2-Piece Flange Nut (Steel Wheels) 27 ft. MAINTENANCE Tires Wheel Installation 1. Torque the wheel nuts to the ground. 6. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. WARNING! Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lower the vehicle to specification.
Owners Manual
Page 91
Oil from the rear of the pod. 4. Hot components can result in the housing. 8. Always make sure lights are adjusted properly for best visibility. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Remove the two screws on the lower front corners of the lamp. 1. Remove the screw from your skin leaves a residue, causing a hot spot...
Oil from the rear of the pod. 4. Hot components can result in the housing. 8. Always make sure lights are adjusted properly for best visibility. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Remove the two screws on the lower front corners of the lamp. 1. Remove the screw from your skin leaves a residue, causing a hot spot...
Owners Manual
Page 94
... the assembly up and out of the headlight pod. 2. Use a small screwdriver to remove the o-rings from the wiring harness. 5. Remove the two screws on the lower front corners of the pod. 9. Pull the headlight housing up to release it from the locking tabs. 7. MAINTENANCE Lights Headlight Housing Replacement 1. Lift the adjusting knob up to remove it from the locking tabs. 8. Lift the pod cover and...
... the assembly up and out of the headlight pod. 2. Use a small screwdriver to remove the o-rings from the wiring harness. 5. Remove the two screws on the lower front corners of the pod. 9. Pull the headlight housing up to release it from the locking tabs. 7. MAINTENANCE Lights Headlight Housing Replacement 1. Lift the adjusting knob up to remove it from the locking tabs. 8. Lift the pod cover and...
Owners Manual
Page 95
... grease to secure the headlamp. Reinstall the harness assembly into the headlight assembly. 4. Harness Taillight/Brakelight Lamp Replacement 1. Turn the lamp counter-clockwise to remove it. 3. Reinstall the harness connector. 5. MAINTENANCE Lights Lower Headlamp Replacement 1. Remove the harness connector Connector from the headlight assembly. 2. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the back of the light assembly. 2. Remove the headlamp and install the...
... grease to secure the headlamp. Reinstall the harness assembly into the headlight assembly. 4. Harness Taillight/Brakelight Lamp Replacement 1. Turn the lamp counter-clockwise to remove it. 3. Reinstall the harness connector. 5. MAINTENANCE Lights Lower Headlamp Replacement 1. Remove the harness connector Connector from the headlight assembly. 2. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the back of the light assembly. 2. Remove the headlamp and install the...
Owners Manual
Page 113
... the following the instructions 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) • Coolant (test strength/fill) Fog the Engine 1. Remove the spark plugs and add 2-3 tablespoons of oil. 3. Turn the engine over several minutes so the Carbon Clean reaches the injectors...
... the following the instructions 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) • Coolant (test strength/fill) Fog the Engine 1. Remove the spark plugs and add 2-3 tablespoons of oil. 3. Turn the engine over several minutes so the Carbon Clean reaches the injectors...
Owners Manual
Page 116
... of control and vehicle overturn. Inspect clutch seals for warm up at low ambient temperatures Solution Use low range during loading. Wrong or missing belt Install the recommended belt. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up belt one mile (5 miles or...
... of control and vehicle overturn. Inspect clutch seals for warm up at low ambient temperatures Solution Use low range during loading. Wrong or missing belt Install the recommended belt. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up belt one mile (5 miles or...
Owners Manual
Page 120
SPECIFICATIONS SPORTSMAN 800 EFI Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
SPECIFICATIONS SPORTSMAN 800 EFI Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
Owners Manual
Page 121
SPECIFICATIONS SPORTSMAN 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi (34.5 KPa) 25x11-12 / 5 psi (34.5 KPa) Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on...
SPECIFICATIONS SPORTSMAN 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi (34.5 KPa) 25x11-12 / 5 psi (34.5 KPa) Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on...
Owners Manual
Page 124
... components; The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to the product only and does not allow for commercial purposes. improper fuel; use of aftermarket components resulting in failure; Warranty will not apply to...
... components; The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to the product only and does not allow for commercial purposes. improper fuel; use of aftermarket components resulting in failure; Warranty will not apply to...
Owners Manual
Page 129
... of the vehicle owner. This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units...
... of the vehicle owner. This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units...
Owners Manual
Page 135
......98 Lower Headlamp Replacement...91 Lubrication Guide ...69 S Safe Operation Practices...47 Safety Labels ...22-25 Safety Training ...7 Safety Warnings ...11-21 Service Interval Programming ...40 Severe Use ...64 Side Panel Removal ...82 Sidehilling...54 Signal Words ...4 Spark Arrester ...95 Spark Plug Inspection ...92-93 Spark Plug Recommendations ...92 Spark Plug Torque Specification ...92 Spark Plugs ...92-93 Specifications, 800 EFI...117 Spring Adjustment, Rear Shock ...80 M Maintenance Chart ...64-68 Master Cylinder ...30 Mode Switch ...26 Modifications ...9 N Noise Emission Control...
......98 Lower Headlamp Replacement...91 Lubrication Guide ...69 S Safe Operation Practices...47 Safety Labels ...22-25 Safety Training ...7 Safety Warnings ...11-21 Service Interval Programming ...40 Severe Use ...64 Side Panel Removal ...82 Sidehilling...54 Signal Words ...4 Spark Arrester ...95 Spark Plug Inspection ...92-93 Spark Plug Recommendations ...92 Spark Plug Torque Specification ...92 Spark Plugs ...92-93 Specifications, 800 EFI...117 Spring Adjustment, Rear Shock ...80 M Maintenance Chart ...64-68 Master Cylinder ...30 Mode Switch ...26 Modifications ...9 N Noise Emission Control...