Polaris Sportsman 800 Big Boss, Sportsman 800 6X6 User Manual

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922027 Rev 02 Printed in USA

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www .purepolaris.co m. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2008 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 discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2009 Sportsman 800 6X6 Owner’s Manual P/N 9922027

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls. . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Emission Control Systems . . . . . . . . . . . . . . . 66

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 118

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 124

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This Polaris vehicle 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.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating this vehicle. Keep this manual with the vehicle.

• Never operate this vehicle without proper instruction. Take a training course. Purchasers of a new Polaris vehicle and their eligible family members are entitled to take the ATV RiderCourse (800) 887-2887 or visit www.atvsafety .org for information on enrollment in the ATV RiderCoursesm.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

• Never permit a guest to operate this vehicle unless the gue st has read this manual and all product labels and has completed a certified safety training course.

. Contact ATV Enrollment Express at

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

SAFETY

Safety Training

Safety training is a top priority for Polaris. When you purchased your new vehicle, your dealer instructed you on the authorized ATV Rider-

Course

ing is included in the purchase price of your vehicle. Polaris strongly encourages you and your eligible family members who will be riding this vehicle to take the ATV RiderCourse with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris vehicle, you can take the ATV Rider-

Course

visiting www.atvsafety.org. Purchasers of a used Polaris vehicle will be charged for this training.

This Polaris vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

W e strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cp sc.gov, visit www.at vsafety.org, or call Polaris at 1-800-342-

3764.

available to you and your eligible family members. This train-

. You were also provided

by calling ATV Enrollment Express at (800) 887-2887 or by

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established 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 granted approval. The approval number and serial number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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. Riding 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 vehicle 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 vehicle 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) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.

Never permit a guest to operate the vehicle unless the guest has read this manual and all product labels and has 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 Polaris vehicles, he/she may not have the skills, abilities, or judgment needed to operate this vehicle safely and could be susceptible to accident or injury.

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• 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 vehicle is in safe operating condition before operating increases the risk of an accident.

Always inspect the vehicle 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.

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 vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.

Never consume alcohol or drugs before or while operating this vehicle.

Carrying a Passenger

Carrying a passenger greatly reduces the operator's ability to balance and control the vehicle, which may result in an accident or overturn.

Never carry a passenger on this vehicle.

Safety Warnings

Operating on Pavement

Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn.

Avoid operating the vehicle on pavement. The 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 vehicle on public streets, roads or highways could result in a collision with another vehicle.

Never operate the vehicle on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate this type of vehicle on public streets, roads and highways.

Operating at Excessive Speeds

Operating the vehicle 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

Safety Warnings

Physical Control of the Vehicle

Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the vehicle. If the operator's foot is not firmly planted on the 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 55. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill.

SAFETY

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

• Always follow proper procedures for traveling down hills as described in the own e r 's manual. NOTE: A special technique is required when braking while traveling downhill. See page 57.

• Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36.

• Always check the terrain carefull y before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• 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 56.

Never attempt to turn the vehicle around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 58.

SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.

• Always maintain a steady speed when climbing a hill.

• Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the service brakes.

• Lock the parking brake when fully stopped.

• Dismount on uphill side, or to either side if the vehicle is pointed straight uphill.

• Turn the vehicle around and remount, following the procedure described in the owner's manual. See page 58.

If the vehicle begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolli ng backwards. Apply the service brake gradually.

• When fully stopped, apply the rear brake as well, and then lock the parking brake.

• Dismount on uphill side, or to either side if the vehicle is pointed straight uphill.

• Turn the vehicle around and remount, following the procedure described in the owner's manual. See page 58.

Safety Warnings

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn.

Never operate on hills too steep for the vehicle or for your abilities. Never operate the vehicle on hills steeper than 25 degrees.

Operating on Slippery Terrain

Failure to use extra 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.

SAFETY

Safety Warnings

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure as described in the owner's manual and on safety labels.

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 60.

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.

SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the vehicle or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.

• Never exceed the stated load capacity for

this vehicle.

• Cargo should be properly distributed and

securely attached.

• Reduce speed when carrying cargo or pull-

ing a trailer. Allow a greater distance for braking.

• Always follow the instructions in the owner's manual for carrying cargo or pull-

ing a trailer.

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 61.

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

Poor Visibility

Operating the vehicle in darkness o r inclement weathe r could result in a collisi on or accident, especially if operating on a road or street. This vehicle 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.

SAFETY

Safety Warnings

Operating Through Deep Water

Operating the vehicle through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn.

Avoid operating the vehicle through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page

59):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• 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.

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the vehicle and/or the operator fall through the ice.

Never operate the vehicle on a frozen body of water.

SAFETY

Safety Warnings

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this veh icle 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. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the Vehicle

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.

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for yo ur protection. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact 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 vehicle use can result in SEVERE INJURY or DEATH

NEVER:

• Operate on public roads. A collision can occur with another vehicle.

• Carry passengers. Passengers affect balance and steering and increase risk of losing control.

• USE ALCOHOL or DRUGS before or while operating this vehicle.

• Operate at speeds too fast for your skills or the conditions.

• Operate this vehicle on HILLS steeper than 25 degrees. To prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

• Use an approved HELMET AND PROTECTIVE GEAR.

• Avoid paved surfaces. Pavement may seriously affect handling and control.

• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns.

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

REVERSE operation can be dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sharp turns.

PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONT ACT A POLARIS DEALER FOR A REPLACEMENT.

7175784

Safety Labels and Locations

Tire Pressure/Load

Warning

Reverse Override

Warning

Front Rack

Warning

General 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.

• Cold tire pressure:

Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa) Rear: 10.0 psi (68.9 kPa)

• Maximum weight capacity: 1115 lbs. (507 kg)

SAFETY

7175651

Front Rack/Box Warning

WARNING

• 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.

• Max. Rack Loads: 100 lbs. (45 kg)

Reverse Override Warning

WARNING Improper use of override button can lead to loss of contro l resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

7175662

7175486

SAFETY

Clutch Cover

Warning

Age 16 Warning

Container/No Passenger

Warning

Safety Labels and Locations

Container/No Passenger Warning

WARNING Remove flammable containers from box before refueling. WARNING

• Passengers can be thrown off. This can cause serious injury or death.

• Never carry passengers.

Maximum Box Load 800 lbs. (363 kg)

7079316

SAFETY

Safety Labels and Locations

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.

7172588

Clutch Cover Warning

WARNING

• 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

7172563

Hitch Capacity Label

TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

9921509

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

4X4

Switch

Switches

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, release the throttle and depress the override button.

WARNING! Pressing the override button while the throttle is open can cause 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 4X4 in reverse, if the 4X4 switch is on. This switch is also used to toggle through the modes of the rider information center. See page 37.

All Wheel Drive (AWD) Switch

See page 34 for AWD information.

FEATURES AND CONTROLS

OFF OFFRUN

Switches

Engine Stop Switch

Move the stop switch either left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off.

Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 51 for starting procedures.

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.

+ 106 hidden pages