Home

Polaris 800 EFI Touring Offroad Vehicle User Manual

Contents

1. 89 Winch Cable Care 64 Winch Operation 67 68 Winch Preparation and Inspection 65 Winch Rigging 66 Winch Safety Precautions 63 PMS 419 Before you operate this vehicle read the owner s manual For your nearest Polaris dealer POLARIS call 1 800 POLARIS The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923428 Rev 02 Printed in USA a
2. 86 Carlos hs 2a5 hie Veoh ek Sas 60 61 Caster Adjustment 86 Chrome Wheel Care 113 Cleaning and Storage 111 116 Clothing 2 0005 9 Clutching 0 123 Codes vias aana OAS EA 41 43 Cold Weather Operation 49 Consumer Product Safety 7 Coolant Bottle 82 Coolant Radiator 83 Cooling System 82 83 Corrosion Removal Chrome 113 130 D Demand Drive Capacities 81 Demand Drive Fluid 81 Downloading Codes 41 43 Drive Belt Wear Burn 118 Drivetrain Break In 45 Driving Downhill 55 Driving in Reverse 59 Driving on a Sidehill 54 Driving on Slippery Surfaces 52 Driving Over Obstacles 58 Driving Procedures 50 Driving Through Water Sf Driving Uphill 0 53 E Electromagnetic Interference 69 Engaging AWD 34 Engine Break In 45 Engine Fogging 115 Engine Oil 76 78 Equipment Modifications 9 Etiquette Trail Riding 48 European Vibration and Noise 69 Exhaust Emission Control System 69 Eye Protection 9 F Fluid Brake Fluid 30 Demand Drive Fluid 81 Engine Oil 76 78 Transmission Fluid
3. 79 80 Fluid Change Demand Drive Fluid 81 Engine Oil 77 78 Transmission Fluid 80 Foot Brake Auxiliary 32 Footwell Removal 88 Front Gearcase Demand Drive 81 Fuel Safety 00 11 Fuel Tank Capyie s eni rioter ota 33 Fuse Replacement 92 G Gasoline Handling 11 Gear Selector 33 GOVES sisi ais Fe BG ach ee he REA 9 H Hand Brakes oi we eet gas et den 84 Handlebar Adjustment 86 Hauling Cargo 60 61 Headlight Housing Replacement 96 Headlight Lamp Replacement 93 Headlight Switch 27 Helmet to ctice anea as Ea a 8 High Beam Adjustment 94 High Range Use 104 l Idle RPM Adjustment 87 Timersion e s ea cay ees et eee ah 100 Instrument Cluster 35 43 K Key Switch 0 27 KTU eer en ee ee 56 L Light Switch 0 26 Lights cess eee 93 97 Headlight Housing Replacement 96 Headlight Lamp 93 High Beam Adjustment 94 Low Beam Adjustment 95 Lower Headlamp Replacement 97 Taillight Brakelight Worklight 97 Low Beam Adjustment 95 Low Range Use 104 Lower Headlamp Replacement 97 Lubrication Guide 75 M Maintenance Chart 70 74 Master Cylinder 30 Mode Swi
4. A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION 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 A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV e Never operate an ATV without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course INTRODUCTION Vehicle Identification Numbers R
5. Foot Activated Hydraulic Disc Brake Parking Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mounting for attachment of coupling devices Winch Front permanent installed winch with 2500 Ibs 1125 kg capacity Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 62 Black Black Almond 48 54 Feet 0 6000 PN 5632337 PN 7043594 PN 7043167 Progressive 1800 3700 23 58 Black Black Almond 48 54 6000 12000 PN 5632218 PN 7043594 PN 7043167 Progressive 123 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 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 1 2878069 AGL PLUS Transmission Fluid gal 3 8 I 2877922 Demand Drive Plus Fluid qt 95 1 2877923 Demand Drive Plus Fluid gal 3 8 I 2871653 Premium ATV Angle Drive Fluid 8 oz 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 60 40 Coolant g
6. WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 ONO ON En On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover if equipped Secure the battery hold down strap Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 107 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 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 124 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the batt
7. 11 25 in 28 5 cm Minimum Turning Radius 65 in 165 cm unloaded Engine SPM800 4 Stroke Low Torque Capacity Displacement 760 cc Engine Power 41 kW Bore x Stroke 80 x 76 Alternator Output 500 Watts 3000 rpm Compression Ratio 10 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Ignition Timing 8 BTDC 2000 RPM Spark Plug Gap RC7YC 035 in 0 9 mm Lubrication System Pressurized Wet Sump Seat Single Seat length 650 mm Steering System Transmission Power System Akerman Principle with handlebar controls Shaft drive on all wheels Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel Based on EU Directive 76 432 EC 122 SPECIFICATIONS SPORTSMAN FOREST 800 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 Off Road Style Deep Tread Design Size 25x8 12 5 psi 34 5 KPa Tires Pressure Rear Off Road Style Deep Tread Design Size 25x11 12 5 psi 34 5 KPa Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brakes Auxiliary
8. Open Load Short to Ground 37 Ignition Coil B Prim Sec Circuit Malfunction Shorted Load Short to Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure Manifold Air Pressure Sensor Low 46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to Ground 55 MIL Circuit Shorted Load Short to Battery 56 Fuel Pump Open Load Short to Ground 56 Fuel Pump Shorted Load Short to Battery 58 Fan Circuit Open Load Short to Ground 58 Fan Circuit Shorted Load Short to Battery 63 Starter Enable Open Load Short to Ground 63 Starter Enable Shorted Load Short to Battery 72 Gear Sensor Signal 73 4X4 Open Load Short to Ground 73 4X4 Shorted Load Short to Battery 74 Rear Differential Enable Open Load Short to Ground if equipped 74 Rear Differential Enable Shorted Load Short to Battery if equipped 61 END SEQUENCE 43 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or
9. alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 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 If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience SAFETY 13 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or fee
10. 26 The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the ATV Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Small fluctuations in the RPM from day to day may be normal because of changes in humidity temper ature and elevation 37 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 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens 38 FEATURES AND CONTROLS Instrume
11. Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 109 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of 3 Charge Time 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 from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 110 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
12. NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 111 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 e Wheel bearings e Electrical components e Radiator e Switches and controls Transmission seals e Fuel system components e Cab and body panels e Labels and decals If an informational or graphic label becomes illegible or com
13. hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 22 SAFETY Safety Labels and Locations General 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 e Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa e Maximum weight capacity 515 Ibs 234 kg Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees lt lt 25 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill e REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns Discretionary 23 SAFETY Safety Labels and Locations Age 16 No Passenger Warning Warning Rack Rack Warning Warning Hitch Capacity Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger a ae can cause a loss of control resulting in SEVERE INJURY or Age 16 Warning WARNING Operating 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 24 SAFETY Safety Labels
14. kg and or front cargo loads are above 37 lbs 17 kg Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 60 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 NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 Ibs 17 kg When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle e Unbraked Trailer Towing Capacity is 1914 lbs 868 kg based on EU D
15. plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 45 118 Engine Doesn t Turn Over Possible Cause Tripped circuit breaker or blown fuse TROUBLESHOOTING Solution 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 Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spar
16. 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 Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operating 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 Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 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 Using Alcohol or Drugs Operating the ATV after consuming
17. the adjusting knob 96 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 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light Connector lt s assembly L 2 Turn the lamp counter clock wise to remove it YAW 3 Apply dielectric grease to the N lt Cia socket and install the new i lamp 4 Reinstall the harness connector 5 Test the light for proper operation 97 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 use POLARIS recommended spark plugs Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has
18. to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plugs Dry the spark plugs Reinstall the plugs or install new plugs Attempt to start the engine If necessary repeat the drying proce dure 3 4 Turn the engine over several times using the electric start 5 6 7 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 104 for drying out the PVT 100 MAINTENANCE Spark Arrester AWARNING Failure to heed the following warnings while servicing the spark arrester 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 or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler Be sure to
19. to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement l 2 40 Enter the diagnostic mode Toggle to the screen that displays either kilometers KM or miles MP Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 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 l 2 3 4 Place the transmission in PARK Stop the engine Turn the key switch to the ON position Turn the key switch off and on three times in less than five seconds then leave the s
20. 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Add coolant as needed Recovery Bottle 82 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 If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover 2 Remove the access panel screws Squeeze the outer edges of the panel inward to remove the panel 3 Remove the pressure cap 4 Using a funnel slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 6 Reinstall the access panel and secure the front box cover 83 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 op
21. 4 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 70 e 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 l Treat the fuel system with POLARIS Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 115 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 70 Batt
22. AWD while the rear wheels have traction or are at rest 34 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 It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph 11 14 km h Refer to page 26 for additional information Speedometer Needle Speedometer Rider aN I iS Information Center NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 35 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 If this occurs take the ATV to yo
23. Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Have an authorized POLARIS dealer perform these services 74 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 70 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 However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion MAINTENANCE Item Lube Capacity at Inspection Fluid Change Procedure Engine Oil PS 4 PLUS Performance 2 qt 1 9 I See page 76 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 30 Transmission Oil AGL PLUS Transmission 32 oz 946 ml See page 79 Fluid Demand Drive Demand Drive Plus Fluid 9 oz 265 ml See page 81 Fluid Front Gearcase Front Prop Shaft Yoke POLARIS Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke 75 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 Oi
24. Inspect and clean or replace See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 120 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution 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 Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrec
25. Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 47 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 Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect fo
26. PMS 419 CH POLARIS The Way Out Sportsman Forest 800 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 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 e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period For more information about POLARIS visit us online at www pola risindustries com POLARIS The Way Out POLARIS THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc Copyright 2011 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the infor
27. RRANTIES 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 e Wheels and tires e Finished and unfinished surfaces e Suspension components Carburetor Throttle body components e Brake components Engine components e Seat components Drive belts e Clutches and components e Hydraulic components Steering components Circuit breakers Fuses e Batteries Electronic components e Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim e Spark Plugs e Lubricants such as oil grease etc e Filters Batteries unless defective e Fuel Cosmetic damage repair e Sealants Coolants Hotel fees e Meals e Towing charges Shipping handling fees e Mileage e Product pick up delivery e Rentals Loss of product use e Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper co
28. al 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 02z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 124 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 This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase The duration of this warranty may vary depending on location This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration f
29. and Locations Clutch Cover Warning WARNING e 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 NO STEP Rack Warning Front and Rear WARNING e DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch e Max Rack Loads Front 100 Ibs 45 kg Rear 200 Ibs 91 kg Reverse Override Warning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse 25 FEATURES AND CONTROLS Switches Headlight Engine Switch Stop Switch Switch Mode Reverse Main Key Switch an Winch 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 WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The override switch also allows activation of AWD in reverse if the AWD switch is on Thi
30. arm up at idle for two to three min utes Stop the engine Clean the area around Drain Plug Location the drain plug Place a drain pan 5 z j under the crankcase pa SE j a i biklo Solel Mo 2 Ie Binal Remove the drain TES ho e plug Allow the oil to n drain completely gt to front CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 10 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft Ibs 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench available from your POLARIS dealer turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase 77 MAINTENANCE Engine Oil Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 21 78 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 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 Remove the dipstick Add two quarts 1 9 1 of recommended oil Place the transmission in PARK Lock the park
31. ash back with dangerous force 3 Beware of the danger zone The danger zone is the area of the rotating wire cable drum the fairlead if fitted the cable the hook and the motor Before placing hands in or near the danger zone first relieve tension on load then disconnect the control switch 4 Ifyou are within four feet of the winch do not hold the cable and the remote if equipped at the same time 63 WINCH GUIDE Winch Cable Care l The life of a cable is directly related to the care it receives The wire cable on a new winch and any replacement cables must be re spooled under a minimum of a 100 lb 45 4 kg load before use Failure to do this will result in cable damage Inspect all cable before use Mashed pinched frayed or kinked areas severely reduce the load carrying capability Replace dam aged cable promptly Prevent kinks before they occur Am A This is a start of a kink Straighten Og sss the cable before using it B The cable was pulled and the loop has tightened to a kink The cable is now permanently damaged and should not be used B y Paa C The result of kinking is that each ss strand pulls a different amount of load causing the strands under the greatest tension to break This C mm reduces the load capacity of the an entire cable may Before re spooling remove all load from the cable Hold the han dlebar switch lead in one hand and the cable in the other Move awa
32. been driven at higher speeds Immediately check the spark plugs for correct color See page 99 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 98 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 A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 99 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
33. brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Foot Brake Fluid Reservoir Check the brake fluid level fre quently for the auxiliary brake system The reservoir is located under the seat on the left side of the vehicle Maintain the fluid level between the maximum and minimum marks 32 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle High Gear Low Gear Neutral Reverse Park To shift gears brake to a com plete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed Fuel Tank Cap Fuel Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with etha nol
34. city Reinstall the fill plug Torque to 8 10 ft lbs 11 14 Nm Check for leaks Dispose of used fluid properly Dyn ee 81 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 As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 124 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 88
35. clean out both arresters if your model has two Exhaust 2 Place the transmission in PARK Outlet Start the engine 4 Quickly squeeze and release the Clean Out Plug throttle lever several times to purge carbon from the system iv 5 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrester to cool 10 Reinstall the arrester plug and remove the exhaust outlet cover or plug 101 MAINTENANCE PVT System AWARNING 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 modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the followi
36. content greater than 10 percent such as E 85 fuel Gear Selector YZE 33 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 Switch be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 26 Engaging AWD The AWD 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 AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to
37. e loss of control or overturn When ever traveling uphill follow these precautions Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle SO se a 53 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 l pee et 54 Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately OPERATION Driving Downhill When driving downhill follow these precautions l 2 3 4 Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Slow down Excessive speed when traveling downhill can cause loss of control Squeeze the brake lever gradually Applying the bra
38. e your battery If the low battery warning light comes on stop winching Make sure the transmission is in neutral or park then rev the motor for a few minutes until the warning light goes out Recharge the battery as soon as possible 7 DO NOT overload or stall the winch If the load is greater than the winch is capable of pulling use a snatch block 8 Avoid continuous side pulls Never tow the vehicle by the winch cable 10 Never use the winch cable as a tie down SR TO Ne 11 Use an anchor point that is stronger than what you are pulling 12 DO NOT hook the cable back onto itself This will damage the cable 67 WINCH GUIDE Winch Operation 13 Use as much cable as possible when pulling Additional wraps of cable on the spool will significantly reduce the pulling power of your winch If the winch is still not capable of pulling the load use a snatch block 14 Never pull with less than five wraps of cable on the spool 15 Inspect the condition of the cable prior to pulling If the cable is frayed or damaged replace it as soon as possible 16 DO NOT submerge the winch in water 68 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on road and off road operation It is required that this spa
39. ease 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 Reinstall the pre filter over the main filter Install a new main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air box cover and the seat 91 MAINTENANCE Fuse Replacement Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A Main Fuse Ignition Lighting 20A 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 Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the front box cover 92 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 visib
40. ecord 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 The ignition switch must be replaced if all keys are lost Engine Serial Number VIN front or rear frame Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training Never operate this vehicle without proper instruction Take a training course For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polarisindustries com SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Helmet Long Sleeves Gloves Long Pants 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 Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval nu
41. elt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 104 MAINTENANCE Battery AWARNING 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 AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one table
42. er with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice condi tions and thickness over your entire route ATV operators assume all risk associ ated with ice conditions on frozen bodies of water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 20 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 Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Alway
43. eration 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 To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 30 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 32 84 Toe Alignment MAINTENANCE 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 t
44. erson 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 When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV 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 ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels 18 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 See page 58 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to ente
45. ery Maintenance Remove the battery and recharge it as outlined on page 109 Store the battery in a cool dry place Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensa tion and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your POLARIS dealer 116 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 Do not attach tie straps to the front BN Va A arm bolt pockets racks or handlebars 6 Remove the key to prevent m loss during transporting 7 di 117 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Soluti
46. ery reed hee fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 108 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 106 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 107 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch
47. es off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 112 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 Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automot
48. est system yearly Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month Oil filter change 100 H 6M 1000 1600 Replace with oil change Valve clearance 100 H 12 M 1000 1600 Inspect adjust Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years Radiator 100 H 12M 1000 1600 Inspect clean external surfaces Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 12M 1000 1600 Inspect replace as needed Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 73 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km H Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years gt Fuel filter 200 H 24M 2000 3200 Check for leaks around lines E Replace every 2 years more often under extreme conditions Spark arrester 300 H 36 M 3000 4800 Clean out E Toe adjustment Inspect periodically adjust when parts are replaced
49. g Adjustment Rear Shock 86 Starting the Engine 49 Steering Assembly 88 Stota pEr nit hs ty eee 111 116 Storage Tips 114 116 Switches AWD Switch 26 34 Engine Stop Switch 27 Headlight Switch 27 Main Key Switch 27 Mode Switch 26 Reverse Override Switch 26 Stop Switch 0 27 Winch Switch 26 T Taillight 0 236 nen cet av etaa 97 Throttle Body Adjustment 87 Throttle Cable Freeplay Adjustment 87 Throttle Lever 28 Tire Tread Depth 89 TIRES ensenen neaken nekep ae 89 90 Wheel Installation 90 Wheel Nut Torque 90 Wheel Removal 89 132 T Toe Alignment 85 Towing Loads 61 Trail Etiquette 0002 48 Training 2 2 ee ee eee eee 7 Transmission Gear Selector 33 Transmission Oil 79 80 Transmission Oil Recommendations 79 Transporting the Vehicle 117 Tread Lightly 48 Turning Around ona Hill 56 Turning the Vehicle 51 V Vehicle Identification Numbers 6 Vehicle Immersion 100 Ww Warning Symbols 4 Washing the Vehicle 111 112 Wheel Hub Tightening 89 Wheel Installation 90 Wheel Nut Torque Specifications 90 Wheel Removal
50. ghtening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 89 MAINTENANCE Tires Wheel Installation 1 Place the transmission in PARK 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 vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 30 ft Ibs 41 Nm Wrealsy PLUS 1 4 TURN eels 2Piece O 27 ft Ibs 37 Nm ange Nu Steal NO Wheels 90 MAINTENANCE Air Filter 1 Remove the seat Pre Filter 2 Rel
51. gine stop switch Ensure proper operation 27 Air filter pre filter Inspect clean 91 Air box sediment tube Drain deposits whenever visible Headlamp ale operation apply POLARIS 27 ielectric grease when lamp is 93 replaced Brake light tail lamp Check operation apply POLARIS 97 dielectric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing Winch Inspect cable and switch 64 65 46 OPERATION Safe Operation Practices l 2 10 11 12 13 14 Complete the recommended safety training before operating this vehicle See page 7 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 Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds
52. h their function and effect on the vehicle SAFETY 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 Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Never permit others to operate the vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury 10 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline e Always refuel with the engine
53. he engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail 103 MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low 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 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 the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for b
54. iliar terrain Not all obstacles are immediately visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse TOY eh a a Dn pE Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 59 OPERATION Hauling Cargo AWARNING 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 NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the traile
55. ility Headlight Lamp Replacement When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counter clockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 93 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 94 25 ft 7 6 m os 2 6 cm 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 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The mo
56. ing brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70 Maintain the oil level at the bottom of the fill plug hole threads See page 124 for the part numbers of POLARIS products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Fill Plug Drain Plug Transmission Oil Recommendations Lubricant Capacity Fill Plug Drain Plug Torque Torque AGL PLUS Transmission Fluid 32 oz 10 14 ft Ibs 10 14 ft Ibs 946 ml 14 19 Nm 14 19 Nm 79 MAINTENANCE Transmission Oil Oil Check Fill Plug Fill Level 1 Position the vehicle on a level _s surface 2 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 4 Reinstall the fill plug Torque to specification Oil Change l 2 e ee 9 80 Remove the fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clea
57. ionally during operation Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns to idle when the lever is released Ui oy This ATV is equipped with gt ae POLARIS Electronic Throttle Con trol ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 28 FEATURES AND CONTROLS Brake Lever AWARNING 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 These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should fee
58. irective 76 432 EC NOTICE Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 4 10 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your POLARIS ATV Always install POLARIS approved or equivalent accessories designed for ATV use 61 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions l 2 3 4 62 Stop the engine Place the transmission in PARK Lock the parking brake Always block the rear wheels on the downhill side WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you the operator Read and understand all safety precautions and oper ating instructions before operating the winch Careless operation can result in serious injury DO NOT use the winch to lift or move people Winch Safety Precautions 1 Be alert Do not operate the winch under the influence of drugs alcohol or medication 2 Practice using the winch so you are prepared to use it in an emer gency situation AWARNING Never connect DC powered winches to AC current Motor damage or fatal shock may occur A DANGER Stand clear of the cable and load during winching Keep helpers and spectators at a safe distance If a cable pulls loose or breaks under the load it can l
59. ive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 113 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 111 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 77 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Drain the sediment tube 11
60. k from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 119 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution 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 Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Reverse speed limiter malfunction
61. kes too firmly may cause the rear wheels to lock which could result in loss of con trol 55 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 56 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground 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 2 Choose a crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can resu
62. l firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 29 FEATURES AND CONTROLS Master Cylinder Brake Fluid AWARNING 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 The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master Master Cylinder cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of the master cylin Indicator der The eye will appear dark Window when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low add DOT 4 brake fluid only Do not overfill 30 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 squee
63. l may need to be changed more frequently if POLARIS oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 124 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Level Access the oil dipstick and fill tube from the left side of the ATV 1 Position the vehicle on a level surface 2 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick completely but do not lock it The dipstick must be inserted completely to keep the angle and depth of the stick consistent Dipstick 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dip stick Always read the level on the upper surface of the dipstick 5 After reinstalling the dipstick seat the lever lock Check Level on Top Side 76 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 70 Always change the oil filter whenever changing oil l 2 3 Position the vehicle on a level surface Start the engine Allow it to w
64. lt if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 70 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil if equipped and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 100 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 57 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 58 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfam
65. lusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if incon sistent with controlling state law 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 do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law Y HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a POLARIS dealer authorized to repair POLARIS ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTA TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS sug gests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other war
66. mation presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2012 SPORTSMAN FOREST 800 Owner s Manual P N 9923428 2 TABLE OF CONTENTS Introduction 3 2 56 cb sa kase Recess ee eed ot 4 Safety 221d 255 tame aoa Game ere he we ae 7 Features and Controls 5055 26 Operation 00 03606 ees tease ee tek eee 44 Winch Guide ici siesta eee ven ee ioe 63 Emission Control Systems 69 Maliht6nanGe s 0t33 tect vue vise em aenw ts 70 Troubleshooting 000e5eeees 118 specifications sssceives sconce tiie tes 122 POLARIS Products 000006 124 Warranty ii0 23 2200654 04 40 6 2 606 055 Fe OO s 125 Maintenance Log 22 000000e 128 Index ct 6c tt ee ee eye tee ee is Sa gate 130 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 A The safety alert symbol indicates a potential personal injury hazard WARNING
67. mber and serial 0006 31 number will also be displayed on the label 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 Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself wit
68. mponent alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 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 THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAM AGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exc
69. n apply dielectric grease if replacing gt Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed if applicable check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically E Battery 20 H Monthly 200 320 Check terminals clean test gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped gt Perform these procedures more often for vehicles subjected to severe use m Have an authorized POLARIS dealer perform these services 72 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate ETC Switch replace if necessary Throttle Body 50 H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure t
70. n and reinstall the drain plug Torque to specification Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Dispose of used oil properly 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 70 We rec ommend the use of Demand Drive Plus Fluid Use of other fluids may result in improper operation of components See page 124 for the part numbers of POLARIS products Maintain the fluid level at the bottom of the fill hole threads See below for capacity Demand Drive Capacity Demand Drive 9 oz 265 ml The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the All plug Torque to 8 10 ft Ibs Fill Level brain Plug 11 14 Nm Fluid Change 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add the recommended fluid See table above for capa
71. ng responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt e See your dealer as outlined in the owner s manual e This PVT system is intended for use on POLARIS products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 102 MAINTENANCE PVT System PVT Operation 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 Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On POLARIS ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the oper ation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to t
72. not descend a hill with the transmission in neutral e Always check the terrain carefully before descending a hill e Shift your weight rearward e Never travel down a hill at high speed e Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides 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 hillside is unavoidable always follow proper procedures as described in the owner s manual See page 54 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 56 15 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn e Always maintain a steady speed when climbing a hill If all forward speed is lost e Keep body weight uphill Apply the brakes e Lock the parking brake when fully stopped e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 56 If the ATV begins rolling downhill e Keep body weight uphill e Never apply engine power e Never a
73. nt 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 This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 40 The service interval is programmed at 50 hours at the factory 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval l 2 3 Enter the diagnostic mode Toggle to the service interval screen 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 To reset the service interval l 2 3 Enter the diagnostic mode Toggle
74. nt noise or temperature 69 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 Record maintenance and service in the Maintenance Log beginning on page 128 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser viced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cau
75. o adjust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement aan i 7 String rT fe NG A W Ga 5l cU J 2 gt J 1 gt FRONT should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your POLARIS dealer for service 85 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through your POLARIS dealer Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tigh
76. on Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 56 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 104 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 104 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled
77. or warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 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 warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond POLARIS control 125 WARRANTY LIMITATIONS OF WA
78. 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 your new POLARIS ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gaso line No single action on your part is as important as following the pro cedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 44 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 76 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 46 6 Pull only light loads 7 Change both the oil and
79. pply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 56 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 16 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 Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 17 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or p
80. r oA OPERATION Ko Sy wheels allowing the turn to be made smoothly The same leaning tech nique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 51 OPERATION Driving on Slippery Surfaces Sideways Turn in direction skid of skid Sa D SA ANY L5 KS TA O OD S x o i 7 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 AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 52 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could caus
81. r the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 48 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 4 Sit on the vehicle and move the engine stop switch to RUN m Do not press the throttle while starting the engine 6 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 7 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation Ifthe ATV is used
82. r tongue The combined weight of these items must not exceed the maximum weight capacity CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34
83. r water that exceeds the recommended maximum depth see page 57 Travel slowly e Balance your weight carefully e Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes e Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 19 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 e Never exceed the stated load capacity for this ATV e Cargo should be properly distributed and securely attached e Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking e NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 Ibs 17 kg e Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water unless you have indepen dently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo togeth
84. ranty terms will remain in effect 127 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 128 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 129 INDEX A Accessories 00000 116 Ait Filter 2 2 yah n yan aes eae ees 91 All Wheel Drive System 34 Auxiliary Foot Brake 84 AWD Switch 26 34 AWD System 2 4 34 B Battery 0 eee eens 105 110 Charging Conventional 109 Charging Sealed 110 Charging Sealed 109 Fluid Conventional 108 Installation 107 Removal 106 Stora 1 ee ae ea 108 Belt Lifer cles dass eet ats terse 33 BOOS aas o8 oes Chores tales 9 Brake Fluid Auxiliary Foot Brake 32 Brake Fluid Main Brake System 30 Brake Lever 005 29 Brakes Foot 4644 dessa sues 32 84 Brake Hand Lever 84 Brake Parking 31 Brakelight 97 Brakes ccc eenden en ie he at 84 Break In Period 44 45 Cc Camber Adjustment
85. raps the cable could pull loose from the drum under load 65 WINCH GUIDE Winch Rigging AWARNING Take your time when rigging and use extra caution Improper rigging can result in injury in addition to damage to the vehicle and equipment Never handle the cable or rigging while another person is at the control switch 1 Useanylon sling to attach the cable to an anchor point CAUTION Do not attach the hook back onto the cable Doing so can cause the cable to break AWARNING Always use a handsaver Do not hold the hook with your hand This is important not only when reeling cable in but also when removing cable from the winch under power 2 Run the winch intermittently to take up cable slack When using a pulley block be sure the cable is running E properly in all pulleys before apply Cad ing a load CAUTION Never engage or disengage the clutch if the winch is under load the cable is in tension or the drum is rotating 66 WINCH GUIDE Winch Operation NOTICE This winch is designed for intermittent use Prolonged use may result in damage due to overheating Use common sense Take your time Think through the situation Pay attention to what is going on when you are winching DO NOT overheat the winch motor During extended winching stop and feel the winch motor The motor should be cool enough to touch If not allow the motor to cool before continuing 6 Extended winching will discharg
86. rk arrester remain installed and functional when the vehicle is operated Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable Electromagnetic Interference This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was con trolled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty e Variations in the machine such as wear of components e Variation of machine operators such as experience or physique e Ability of the worker to reproduce typical work during measurements e Environmental factors such as ambie
87. s keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 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 If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on
88. s switch is also used to toggle through the modes of the rider information center See page 35 AWD Switch Use the AWD switch to engage 4X4 or 2X4 See page 34 Winch Switch See page 63 for winch information 26 FEATURES AND CONTROLS Switches Engine Stop Switch gt Move the stop switch either left or right to the OFF position al to stop the engine quickly The OZS engine will not start or run OFF RUN OFF 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 Main Key Switch Use the main key switch to start the engine See page 49 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 27 FEATURES AND CONTROLS Throttle Lever AWARNING 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 Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occas
89. se or see your dealer 70 MAINTENANCE Periodic Maintenance Chart AWARNING 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 gt Perform these operations more often for vehicles subjected to severe use m Have an authorized POLARIS dealer perform these services 71 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 E Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist gt Front suspension Pre Ride on page 46 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride Winch Pre Ride See pages 64 65 gt Air filter pre filter Daily Inspect clean often replace as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp taillight Daily Check operatio
90. spoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 105 MAINTENANCE Battery Battery Removal Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Nt AE ae 106 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 109 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte
91. st intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counter clockwise 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 down ward 3 Tighten the screw MAINTENANCE V SEE Lid Ly KL aw gemy A O Phillips Screw 95 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod 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 headlamp from the wiring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by turning
92. t Adjuster 87 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 l 2 Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal l 2 3 88 Remove the four screws on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders Remove the footwell MAINTENANCE Tires AWARNING 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 Refer to the specifications section beginning on page 122 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is worn to 1 8 3 mm or less D WG Front Wheel Hub Ti
93. t 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 Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 53 14 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn e 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 See page 55 Always descend a hill with the transmission in forward gear Do
94. t fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 121 SPECIFICATIONS SPORTSMAN FOREST 800 Maximum Weight Capacity 515 lbs 234 kg includes operator cargo accessories Dry Weight 741 Ibs 336 kg 7 based on configuration Fuel Capacity 4 13 gal 15 6 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 3 6 qts 3 4 1 Demand Drive Fluid Capacity Transmission Oil Capacity 9 oz 265 ml 32 oz 946 ml Front Rack Storage Box Capacity 100 lbs 45 kg Rear Rack Capacity 200 Ibs 91 kg Unbraked Trailer Towing Capacity 1914 lbs 868 kg Overall Length 83 in 211 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 50 75 in 128 9 cm Ground Clearance
95. tch 26 Modifications 0 9 INDEX N Noise Emission Control System 69 0 Oil Engine 5 76 78 Transmission 79 80 Oil and Filter Change 77 78 Oil Level Engine 76 Oil Recommendations 76 Override Switch 26 P Parking Brake 31 Parking on an Incline 62 Periodic Maintenance Chart 70 74 Polaris Product List 124 Polishing the Vehicle 112 Pre Ride Checklist 46 PVT Break In 45 PVT Drying 104 PVT System 102 104 R Reverse Operation 59 Reverse Override Switch 26 Rider Information Center 36 43 Riding Area 2 48 Riding Gear 8 9 S Safe Operation Practices 47 Safety Labels 22 25 Safety Training 7 Safety Warmings 11 21 Service Interval Programming 40 Severe Use nce snoras eri sto pes 70 Side Panel Removal 88 Sidehilling 00 54 Signal Words 4 Spark Arrester 00 101 Spark Arrester Requirements 69 Spark Plug Inspection 98 99 Spark Plug Recommendations 98 131 INDEX S Spark Plug Torque Specification 98 Spark Plugs 98 99 Specifications 800 EFI 123 Sprin
96. tening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 5 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 86 Throttle Body Idle RPM MAINTENANCE 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 l 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Boot Lock Nu
97. the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean away all debris when replacing the belt 45 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 Ensure proper operation a Brake fluid Ensure proper level 30 Auxiliary brake Ensure proper operation 32 Front suspension Inspect lubricate if necessary 75 Rear suspension Inspect lubricate if necessary 75 Steering Ensure free operation Tires Inspect condition and pressure 89 Wheels fasteners Inspect ensure fastener tightness a Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 3 Coolant level if applicable Ensure proper level 82 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation ze Indicator lights switches Ensure operation 26 En
98. ur POLARIS dealer for proper diagnosis 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 AWD Indicator This indicator illuminates when the AWD switch is on AWD 3 Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats It also appears if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator 36 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
99. witch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END displays after all codes have been transmitted 41 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 Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim Sec Circuit Malfunction Open Load Short to Ground 36 Ignition Coil A Prim Sec Circuit Malfunction Shorted Load Short to Battery 37 Ignition Coil B Prim Sec Circuit Malfunction
100. y from the vehicle as far as the switch will allow Activate the switch walk in several feet of cable then release the switch Repeat this process until the re spooling is complete CAUTION To avoid injury always release the switch before your hand comes within four feet of the fairlead the physical opening through which the cable passes 5 6 64 Be sure the cable is distributed evenly and tightly on the drum A loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged Do not grease or oil the cable Doing so causes dirt contamination that will reduce the life of the cable WINCH GUIDE Winch Preparation and Inspection A DANGER Wear heavy leather gloves whenever handling cable Do not allow the cable to slip through your hands even with A gloves on When handling the hook A always use a handsaver Never place fingers into the hook Placing fingers in the hook could result in injury A WARNING Inspect the switch and wiring for cracks pinched spots frayed wire or loose connections A damaged shortened lead could cause the winch to operate as soon as it is plugged in A DANGER Never touch the cable or hook while they are in tension or under load Even at rest the winch may have the cable in tension Never guide a cable under tension onto the drum with your hand 1 Winch with at least five wraps of cable around the winch drum With fewer w
101. year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your POLARIS dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 49 OPERATION Driving Procedures XN BOIS ON N a 50 Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 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 To turn steer in the direc tion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rea
102. ze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 31 FEATURES AND CONTROLS Auxiliary Foot Brake AWARNING 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 The rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake The auxiliary foot brake is located Auxiliary Foot Brake on the inside of the right footrest Operate this

Download Pdf Manuals

Related Search

Related Contents

Recomendaciones de trabajo en laboratorio  Central Unit Manual.vp - Close Talk Conference System  Benutzerhandbuch herunterladen  callpilot desktop messaging user guide  microtracteur 26 pouces 5 cv modèle 3594-12 - Societe  取扱説明書 シャーレンチ  Emerson Lorain BD 800 Data Sheet  

Copyright © All rights reserved. Failed to retrieve file