2010 Polaris Sportsman 800 Big Boss 6x6 Problems and Repair Information

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Owners Manual - Page 5

... during, and after, the warranty period. Be sure to return to follow the instructions and recommendations in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician. Your Polaris dealer knows your vehicle, be sure to your dealership for all of apparel, parts and accessories, available through our online...
Owners Manual - Page 11

...manual. If you purchased a new Polaris ATV in your eligible family members. You should review this vehicle in your dealer or local law enforcement agencies for Polaris. This preventive maintenance program is designed to take a training course. Call ATV Enrollment Express at specific...laws and regulations concerning the operation of your vehicle are thoroughly inspected at (800) 887-...
Owners Manual - Page 15

... let it off with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in a short time. Always inspect the vehicle before operating increases the risk of consciousness or death in or near the area where refueling is performed or where gasoline is...
Owners Manual - Page 19

...; Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to turn the vehicle around on any hill unless absolutely necessary. Never attempt to one side. Do not descend a hill with the transmission in the owner's manual. Crossing Hillsides Driving on level ground) as described in forward gear. If...
Owners Manual - Page 20

... the 4X4 switch to either side if the vehicle is pointed straight uphill. • Turn the vehicle around and remount, following the procedure described in the owner's manual. If the vehicle begins rolling downhill: • Keep body weight uphill. • Never apply engine power. • Never apply the rear brake while rolling backwards. Apply the service brake...
Owners Manual - Page 37

... with the engine stopped, and outdoors or in heavy pulling situations and when operating at less than 10 percent, such as E-85 fuel. Fuel Tank Cap 33 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on a level surface. Fuel Tank Cap Always refuel with a minimum pump octane number of the vehicle. Always place...
Owners Manual - Page 40

... ADC system (if equipped) allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low...
Owners Manual - Page 42

... the engine overheats. Serious engine damage could result. 9. If this warning appears. Engine Hour Display Indicator 4. Do not operate the vehicle if this occurs, take the vehicle to clear the warning. 6. Fuel Gauge - When the last segment clears, a low fuel warning is operating at idle and high electrical load (lights, cooling fan, accessories) is located in the fuel tank...
Owners Manual - Page 43

...Hour Meter Mode This mode logs the total hours the engine has been in humidity, temperature and elevation. 39 Tachometer Mode The engine RPM is also the MODE button. FEATURES AND CONTROLS Instrument... trip meter records the miles traveled by the vehicle. Small fluctuations in the RPM from day to day may be in reverse when using this feature. The transmission cannot be normal because ...
Owners Manual - Page 47

... and Failure Descriptions. Place the transmission in less than five seconds, then leave the switch on. See page 45 for all codes have been transmitted. 43 Turn the key switch off and on the screen. The number "61" and the word "END" displays after all major repairs. Any blink code numbers stored...
Owners Manual - Page 50

...vehicle is as important as following the procedures for a proper break-in. Break-In Period The break-in more efficient performance and longer life for your part is the first ten hours of gasoline. Careful treatment of a new engine and drive components will damage close-fitted engine...the time it takes to operate the vehicle properly can result in a collision, loss of control, accident ...
Owners Manual - Page 62

... the parking brake and proceed slowly, controlling speed with the transmission still in forward and shut off the engine. 4. Always move the 4X4 switch to turn the handlebars full left if the vehicle is on more level ground. 58 See page 36. 3. While holding the service brake, release the parking brake lock and slowly allow...
Owners Manual - Page 63

... deep or fast-flowing water. Perform the services outlined in serious engine damage. The following areas need special attention: engine oil, transmission oil, demand drive fluid, rear...before restarting the engine. Maximum Depth NOTICE: Major engine damage can operate through water with a maximum recommended depth equal to the bottom of speed. Transport the vehicle to enter water...
Owners Manual - Page 72

...X Front suspension X Rear suspension Tires X Brake fluid level X Brake lever travel Brake system Wheels/fasteners Frame fasteners X Engine oil level X Air filter, ...Miles (Km) Inspect; Maintenance Chart Key X Perform these operations more often for vehicles subjected to conduct this maintenance will not void the emissions warranty but may result in serious injury or death. Perform all services...
Owners Manual - Page 74

... Q Brake fluid Q ADC fluid (ADC models) X Fuel filter Q E Spark arrestor Q Toe adjustment X Auxiliary brake Q Headlight aim 100 H 200 H 200 H 200 H 200 H 12 M 24 M 24 M 24 M 24 M 300 H 36 M - adjust 620 (1000) Check for vehicles subjected to water, mud, etc. 620 (1000) Inspect; X Perform these services. 70 E Emission-Related Service „ Have an authorized Polaris dealer...
Owners Manual - Page 76

...on a level surface. 2. Always use the recommended oil. Follow the manufacturer's recommendations for this engine. Lift the lever lock to the dipstick entry angle into the crankcase, the oil level will ... Position the vehicle on Top Side Dipstick Safe Add Oil Safe Range 5. Oil Level Access the oil dipstick and fill tube from the left side of Polaris PS-4 PLUS Performance Synthetic 2W-...
Owners Manual - Page 91

... type when replacing tires. Wheel Removal 1. 2. 3. 4. Stop the engine. Elevate the side of the vehicle by your Polaris dealer. 5. All service must be performed by placing a suitable stand under the footrest frame. 6. Remove the wheel. 87 Tire Tread Depth Always replace tires when tread depth is worn to the specifications section beginning on the vehicle. WARNING! Remove...
Owners Manual - Page 116

... allow the stabilizer to disperse through the entire fuel delivery system. See page 73. Allow the engine to run for the recommended amount. Inspect and clean (or replace) the pre-cleaner and air filter. 2. Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended. Oil and Filter Change the oil...
Owners Manual - Page 126

SPECIFICATIONS SPORTSMAN BIG BOSS 6X6 800 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Rear Gearcase Oil Capacity Mid Gearcase Oil Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Cargo Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width...
Owners Manual - Page 137

... physical damage, corrosion or defects caused by a defect in material or workmanship.This limited warranty does not cover damage due to perform any service that has been structurally altered, or when the vehicle has been used in the owner's manual. Tampering with the controlling state law. Polaris also recommends that have any defective materials, components...

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