Polaris Sportsman 800 EFI 4x4 (2012) Service manual

2012-2014 SPORTSMAN 800 / 6X6

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed September 2013 (PN 9924864)

technicians in a properly

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 inaccuracies. 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.

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT(S) MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

GENERAL INFORMATION

MAINTENANCE

ENGINE

FUEL SYSTEM - GENERAL

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL INFORMATION . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. 1.2

MODEL NUMBER DESIGNATION . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION .. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. 1.2

ENGINE NUMBER DESIGNATION .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. 1.3

VIN AND ENGINE SERIAL NUMBER LOCATION . .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 1.3

TRANSMISSION SERIAL NUMBER LOCATION . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . 1.4

SPORTSMAN 800 EFI 4X4 SPECIFICATIONS . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.5

2012-2014 SPORTSMAN 800 EFI . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.5

SPORTSMAN 800 EFI BIG BOSS 6X6 SPECIFICATIONS . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.7

2012–2014 SPORTSMAN 800 EFI BIG BOSS 6X6. .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . 1.7

PUBLICATIONS / PAINT CODES / KEYS / TOOLS .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . 1.9

PUBLICATIONS.. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. 1.9

PAINT CODES . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 1.9

SPECIAL TOOLS . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .1.10

REPLACEMENT KEYS. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .1.10

MISC. NUMBERS/CHARTS . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . 1.11

CONVERSION TABLE .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .1.11

SAE TAP / DRILL SIZES . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 1.12

METRIC TAP / DRILL SIZES .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .1.12

STANDARD BOLT TORQUE SPECIFICATION . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . .1.13

METRIC BOLT TORQUE SPECIFICATION .. . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..1.13

DECIMAL EQUIVALENTS. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .1.14

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.1

GENERAL INFORMATION

MODEL INFORMATION

Model Number Designation

Example: A14KA09AD

GROUP

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th

A 1 4 K A 0 9 A D

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

MODEL

YEAR

CHASSIS

DRIVE-

LINE

ENGINE /

MOTOR CODE

CATEGORY OPTION REGION

Vehicle Identification Number (VIN) Designation

Example: 4XAKA09A0E3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

EN-

WORLD MFG. ID

CHASSIS

DRIVELINE

ENGINE SIZE

GINE MODIFIE-

CATEGORY

CHECK DIGIT

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014

MODEL YEAR *

MFG. LOCATION

INDIVIDUAL SERIAL NO.

1.2

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

GENERAL INFORMATION

Engine Number Designation

EH076OLE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start

VIN and Engine Serial Number Location

The Vehicle Identification Number (VIN) and engine serial number are important for identification purposes. Whenever corresponding about a Polaris utility vehicle, be sure to refer to the VIN and the engine serial number.

The machine VIN is stamped on the lower left side of the frame tube (A).

The engine serial number can be found on the sticker applied to the side of the cylinder head (B). An additional identification number is stamped on the side of the crankcase beneath the oil filter (C).

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.3

GENERAL INFORMATION

Transmission Serial Number Location

The transmission serial number is important for identification purposes. Whenever corresponding about a transmission, be sure to refer to the transmission serial number.

The transmission ID is printed on a label located as shown below.

1.4

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

SPORTSMAN 800 EFI 4X4 SPECIFICATIONS

2012-2014 Sportsman 800 EFI

Model Numbers: A12MH76AX, AZ, FF A13MH76AX, AZ, FF A14MH76AA, AH, FD

CATEGORY

Length

Width 48 in./121.9 cm Height

Seat Height

Wheel Base 50.75 in./128.9 cm

Dry Weight

Front Rack Capacity 100 lbs./45.4 kg

Rear Rack Capacity 200 lbs./90.7 kg

Towing Capacity 1500 lbs./680 kg

Unbraked Trailer Towing Capacity (EU)*

Hitch Tongue Capacity

NOTE: *Data based on EU Directive: 76/432/EEC

DIMENSION / CAPACITY

83 in./210.8 cm

48 in./121.9 cm

33.75 in./85.7 cm

741 lbs./336 kg (cast wheels) 751 lbs./341 kg (steel wheels)

2127.5 lbs. / 965 kg

150 lbs./68 kg Combination of rear rack weight and tongue weight not to exceed 200 lbs. (91kg)

ENGINE

Platform Engine Model Number

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression Pressure 150-200 psi

Engine Idle Speed

Engine Max Operating Rpm

Cooling System / Capacity Liquid - 3.6 qt/ 3.4 ltr.

Overheat Warning

Lubrication Oil Requirements /

Capacity

Exhaust System Single Pipe / Silencer

Fuel System

Fuel Pump 25L per hour at 39 PSI

Fuel Filter(s)

EFI System

Fuel Capacity / Requirement

Electrical Alternator Output (2012) 500 W @ 6000 RPM

Alternator Output (2013 -

2014)

Lights: Pod

Grill 2 x 50 watts Brake 8.26 watts Tail 26.9 watts Worklights

(If equipped)

Ignition Timing 13°BTDC @ 1200 RPM

Spark plug / Gap

Battery / Amp Hr Lead Acid / 30 Amp Hr

Circuit Breakers

GENERAL INFORMATION

Polaris Twin Cylinder

EH076OLE

760cc

80 x 76.5 mm

11:1

1150 ± 100 RPM

6600 Rpm ± 200 Rpm

HOT on Instrument Cluster

Pressurized Wet Sump

Polaris 2W-50 2 qt. / 1.9 liters

30 micron in Tank (unserviceable)

Bosch MSE 1.1B

4.13 gal US / 15.6 liters 87 Octane (minimum) or

89 Oxygenated

500 W @ 3000 RPM

50 watts

2 x 13 watts

RC7YC3/ .035 in. / 0.9 mm

Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 6 amp

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.5

GENERAL INFORMATION

DRIVETRAIN

Transmission Type

Transmission Capacity 33.8 oz. (1000 ml)

Front Gearcase Capacity

Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear)

Clutch Type PVT/ Non-Braking

Steering / Suspension

Front Suspension / Shock

Front Travel 8.2 in. / 21 cm

Rear Suspension / Shock

Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm

Shock Preload Adjustment Front / Rear

Turning Radius

Toe Out

Wheels / Brakes Front Tire Size 25 x 8 - 12 Rear Tire Size 25 x 11 - 12 Tire Pressure F/R

Brake - Front and Rear

Drumshift - H/L/N/ Rev/Park

8.97 / 265 ml

7.70:1/23.91:1

7.00:1/21.74:1

2.67:1/8.28:1

A-arm / MacPherson Strut

Progressive Rate Independent Coil - over shock

Front -Non Adjustable Rear - Ratchet Style- Std.

76 in. / 193 cm 0 - 1/16 in / .0 - .159

5 psi (34.5 Kpa)

Dual Hydraulic Disc

ALTITUDE (METERS (FEET))

0-1800 (0-6000)

1800-3700 (6000-12000)

Clutching

SHIFT WEIGHT

23-62 5632337

23-58 5632218

DRIVE CLUTCH SPRING

Black 7043594

1.6

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

GENERAL INFORMATION

SPORTSMAN 800 EFI BIG BOSS 6X6 SPECIFICATIONS

2012–2014 Sportsman 800 EFI BIG BOSS 6x6

Model Number: A12CF76AA, FF A13CF76AA, FF A14CF76AA, FA

General Specifications

CATEGORY

Length

Width 48 in. / 116.8 cm

Height

Seat Height

Wheel Base 79.5 in. / 201.93 cm

DIMENSION / CAPACITY

112 in. / 284.40 cm

48 in. / 119.4 cm

34 in. / 86.4 cm

CATEGORY

Dry Weight 1060 lbs. / 480.80 kg

Front Rack Capacity 100 lbs. / 45.4 kg

Rear Box Capacity 800 lbs. / 362.87 kg

Towing Capacity 1500 lbs. / 680 kg

Unbraked Trailer Towing Capacity (EU)*

Hitch Tongue Capacity

DIMENSION / CAPACITY

2127.5 lbs. / 965 kg

150 lbs. / 68 kg Combination of rear box and tongue capacity not to exceed 800 lbs. (362.87kg)

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.7

GENERAL INFORMATION

Sportsman 800 EFI BIG BOSS 6x6

ENGINE

PLATFORM

Engine Model Number

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression Pressure 150-200 psi

Engine Idle Speed

Engine Max Operating Rpm

Cooling System / Capacity Liquid - 3.6 qt/ 3.4 ltr.

Overheat Warning

Lubrication Oil Requirements /

Capacity

Exhaust System Single Pipe / Silencer

Fuel System

Fuel System Electronic Fuel Injection

Fuel Pump 25L per hour at 39 PSI

Fuel Filter(s)

EFI System

Fuel Capacity / Requirement

Electrical Alternator Output (2012) 500 w @ 6000 RPM

Alternator Output (2013 -

2014)

Lights: Pod Light

Grill Light

Brake Light

Tail Light

Ignition Timing 13°BTDC @ 1200 RPM

Spark plug / Gap

Battery / Amp Hr Lead Acid / 30 Amp Hr

Circuit Breakers

POLARIS TWIN CYLINDER

EH076OLE

760cc

80 x 76.5 mm

11:1

1150 ± 100 RPM

6600 Rpm ± 200 Rpm

HOT on Instrument Cluster

Pressurized Wet Sump

Polaris 2W-50 2 qt. / 1.9 liters

30 micron in Tank (unserviceable)

Bosch

4.13 gal US / 15.6 liters 87 Octane (minimum) or

89 Oxygenated

500 w @ 3000 RPM

50 watts

Two x 37 watts

26.9 watts x 2

8.26 watts x 2

RC7YC3 / .035 in. / 0.9 mm

Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 6 amp

DRIVETRAIN

Transmission Type

Transmission Capacity

Front Gearcase Capacity- ADC

Mid Gearcase Capacity

Rear Gearcase Capacity

Gear Ratio: Low

Rev High Front Drive Rear Drive

Clutch Type

Steering / Suspension

Front Suspension / Shock

Front Travel 8.2 in. / 21 cm

Rear Suspension / Shock

Rear Travel 6.12 in. / 15.54 cm Ground Clearance 10.50 in. / 26.67 cm

Shock Preload Adjustment Front / Rear

Turning Radius

Toe Out

Wheels / Brakes Front Tire Size 25 x 8 - 12 Rear Tire Size 25 x 11 - 12

Tire Pressure

Brake - Front and Rear

Drumshift - H/L/N/ Rev/Park

17.2 oz. / 510 ml

9.3 oz. / 275 ml

13.5 oz. / 400 ml

5 oz. / 150ml

7.49:1

6.81:1

3.05:1

3.82:1

3.10:1 PVT w/ EBS

A-arm / MacPherson Strut

Progressive Rate Independent Coil - over shock

Front -Non Adjustable. Rear - Ratchet Style- Std.

152 in. / 386.08 cm 0 - 1/16 in / .0 - .159

Front - 7 psi (48.25 Kpa) Rear - 10 psi (69 Kpa)

Dual Hydraulic Disc

Clutching

ALTITUDE (METERS (FEET))

0-1800 (0-6000)

1800-3700 (6000-12000)

SHIFT WEIGHT

21-74 5632117 w/EBS

21-70 5632127 w/EBS

DRIVE CLUTCH SPRING

Red / Blue 7043372 w/EBS

1.8

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

GENERAL INFORMATION

PUBLICATIONS / PAINT CODES / KEYS / TOOLS

Publications

YEA-

MODEL MODEL NO. OWNER'S MANUAL PN PARTS MANUAL PN

Sportsman 800 EFI 4x4

2012

Sportsman 800 EFI

2012

Big Boss 6x6

Sportsman 800 EFI 4x4

2013

Sportsman 800 EFI

2013

Big Boss 6x6

Sportsman 800 EFI 4x4

2014

Sportsman 800 EFI

2014

Big Boss 6x6

Paint Codes

A12MH76AX, AZ, FF

A12CF76AA, FF

A13MH76AX, AZ, FF

A13CF76AA, FF

A14MH76AA, AH, FD

A14CF76AA, FA

9923425 (AX, AZ) 9923428 (FF)

9923404 (AA) 9923408 (FF)

9923794 (AX, AZ) 9923936 (FF)

9923797 (AA) 9923929 (FF)

9924248 (AA) 9924248 (AH) 9924421 (FD)

9924249 (AA) 9924416 (FA)

9923426 (AX, AZ) 9923429 (FF)

9923405 (AA) 9923409 (FF)

9923795 (AX, AZ) 9923937 (FF)

9923798 (AA) 9923930 (FF)

9924643 (AA) 9924643 (AH) 9924644 (FD)

9924604 (AA) 9924752 (FA)

PAINTED PART

Sportsman 800 Frame

COLOR

DESCRIPTION

Black 9440 P-067

DITZLER

NUMBER

POLARIS NUMBER

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.9

GENERAL INFORMATION

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, 1-800-345-2233 or on-line at http://polaris.service-solutions.com/.

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required.

Key Numbers

SERIES # PART NUMBER

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.10

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

GENERAL INFORMATION

MISC. NUMBERS/CHARTS

Conversion Table

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs x 12 = in-lbs

in-lbs x 0.0833

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

grams (g)

pounds (lb) x 0.454 = kg

kilogram (kg)

cubic inches (cu in)

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

liters (L) x 1.057 = US quarts

US gallons

liters (L)

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 1.356 = Nm

x 0.03937 = inch

x 1.6 = km

x 28.35

x .03381

x 0.035

x 2.2046 = lbs

x 16.387

x 0.946

x 3.785

x 0.264

x 0.145

= ft-lbs

= mm

= cm

= grams (g)

= fluid ounces

= ounces

= cc

= liters (L)

= US gallons

PSI

= cylinder volume

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.11

GENERAL INFORMATION

SAE Tap / Drill Sizes

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

#8–32

#8–36

#10–24

#10–32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

F 2–12

U 3–4

THREAD

SIZE DRILL SIZE

1/2–20 29/64

5/8–11 17/32

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

1 59/64

2 3/4

Metric Tap / Drill Sizes

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70 #30 0.1285 1/8

4 x .75

5 x .80 #19 0.166 11/64

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25 17/64 0.265 17/64

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50

12 x 1.50

12 x 1.75 13/32 0.406 13/32

#39

3/32

1/8 0.125 1/8

#20

16/64

5/16

11/32

3/8

13/32

0.0995

0.0937

0.161

0.196

0.234

0.3125

0.3437

0.375

0.406

NEAREST

FRACTION

3/32

5/32

13/64

15/64

9/32

5/16

11/32

3/8

13/32

1.12

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Standard Bolt Torque Specification

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT. LBS. (NM)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

GENERAL INFORMATION

GRADE 5

FT. LBS. (NM)

Metric Bolt Torque Specification

GRADE 8

FT. LBS. (NM)

BOLT

SIZE

M10

M12

M14

M16

M18

GRADE

4.6 4.8 8.8 / 8.9 10.9 12.9

FT.— LBS. (NM) DRY THREADS

.3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 11 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1.13

GENERAL INFORMATION

Decimal Equivalents

FRACTION DECIMAL MM TO INCHES

1/64

1/32 0.0312″ 1 mm = 0.0394″

3/64 0.0469″

1/16

5/64

3/32 0.0938″

7/64

1/8

9/64 0.1406″

5/32

11/64

3/16 0.1875″ 5 mm = 0.1969″

13/64

7/32

15/64

1/4 0.25″

17/64

9/32 0.2813″

19/64 0.2969″

5/16

21/64

11/32 0.3438″ 9 mm = 0.3543″

23/64

3/8

25/64 0.3906″ 10 mm = 0.3937″

13/32

27/64

7/16 0.4375″

29/64

15/32

31/64

1/2 0.500″ 13 mm = 0.5118″

33/64

17/32

35/64 0.5469″ 14 mm = 0.5512″

9/16

37/64

19/32

39/64 0.6094″

5/8

0.0156″

0.0625″

0.0781″ 2 mm = 0.0787″

0.1094″ 3 mm = 0.1181″

0.1250″

0.1563″ 4 mm = 0.1575″

0.1719″

0.2031″

0.2188″

0.2344″ 6 mm = 0.2362″

0.2656″ 7 mm = 0.2756″

0.3125″ 8 mm = 0.3150″

0.3281″

0.3594″

0.375″

0.4063″

0.4219″ 11 mm = 0.4331″

0.4531″

0.4688″ 12 mm = 0.4724″

0.4844″

0.5156″

0.5313″

0.5625″

0.5781″ 15 mm = 0.5906″

0.5938″

0.625″ 16 mm = 0.6299″

FRACTION DECIMAL MM TO INCHES

41/64

21/32 0.6563″ 17 mm = 0.6693″

43/64

11/16

45/64 0.7031″ 18 mm = 0.7087″

23/32 0.7188″

47/64

3/4

49/64 0.7656″

25/32

51/64

13/16 0.8125″ 21 mm = 0.8268″

53/64

27/32

55/64

7/8 0.875″

57/64

29/32

59/64 0.9219″

15/16

61/64

31/32 0.9688″ 25 mm = 0.9843″

63/64

1 1.000″

0.6406″

0.6719″

0.6875″

0.7344″ 19 mm = 0.7480″

0.750″

0.7813″ 20 mm = 0.7874″

0.7969″

0.8281″

0.8438″

0.8594″ 22 mm = 0.8661″

0.8906″ 23 mm = 0.9055″

0.9063″

0.9375″ 24 mm = 0.9449″

0.9531″

0.9844″

1.14

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . 2.3

SPECIAL TOOLS . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 2.3

OVERVIEW . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.3

PERIODIC MAINTENANCE CHART. . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 2.4

LUBRICANTS / SERVICE PRODUCTS. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 2.7

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . .. .. . . . .. . . . . . .. . . . . . .. . . . . . 2.7

LUBRICATION / FLUIDS . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . 2.8

PRE-RIDE / DAILY INSPECTION. . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. 2.8

LUBRICATION / GREASE POINTS (4X4) . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . 2.8

LUBRICATION / GREASE POINTS (6X6) . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . 2.9

ENGINE OIL LEVEL.. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. . .2.10

OIL/FILTER CHANGE . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. 2.11

FRONT GEARCASE LUBRICATION (4X4).. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.12

FRONT GEARCASE LUBRICATION (6X6).. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.13

ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE (6X6) . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .2.14

TRANSMISSION LUBRICATION (4X4) .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. ..2.15

TRANSMISSION LUBRICATION (6X6) .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. ..2.16

MIDDLE GEARCASE LUBRICATION (6X6). . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.17

REAR GEARCASE LUBRICATION (6X6) . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..2.18

VEHICLE INSPECTION . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..2.19

SHIFT LINK ROD INSPECTION (4X4) . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .2.19

SHIFT LINK ROD INSPECTION (6X6) . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .2.19

THROTTLE INSPECTION . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.19

THROTTLE CABLE / THROTTLE RELEASE SYSTEM (TRS SWITCH) ADJUSTMENT . .. . . . .. .. . . .2.20

FUEL SYSTEM . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .2.20

VENT LINES . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.20

COMPRESSION TEST . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.21

ENGINE MOUNTS . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.21

SPARK PLUG. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . .2.22

BATTERY MAINTENANCE . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .2.23

COOLING SYSTEM . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .2.24

COOLANT STRENGTH / TYPE.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .2.24

COOLING HOSES .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .2.24

RADIATOR.. .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . ..2.24

COOLING SYSTEM PRESSURE TEST.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..2.24

RESERVOIR LEVEL INSPECTION . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.25

RADIATOR COOLANT LEVEL.. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .2.25

RADIATOR/GRILL SCREEN .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . .2.26

AIR FILTER/PRE-FILTER SERVICE . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.27

AIR BOX SEDIMENT TUBE . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .2.28

ENGINE BREATHER HOSE . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . ..2.28

PVT INSPECTION / DRYING PROCEDURE .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.29

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.1

MAINTENANCE

ENGINE GROUND . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . .2.29

CAMBER/CASTER. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.30

STEERING INSPECTION .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.30

TIE ROD / STEERING. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .2.31

WHEEL ALIGNMENT . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.32

TOE ALIGNMENT. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .2.32

EXHAUST PIPE. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . ..2.33

BRAKE SYSTEM INSPECTION . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.34

BRAKE PADS. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.35

BRAKE HOSE INSPECTION .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .2.35

AUXILIARY BRAKE TESTING .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .2.35

AUXILIARY BRAKE ADJUSTMENT . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . .. .2.36

SUSPENSION: SPRING PRELOAD ADJUSTMENT . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . .2.36

FRONT SUSPENSION . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..2.36

REAR SUSPENSION . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .2.36

CV SHAFT BOOT INSPECTION. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. .2.37

ATV CONTROLS. .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.37

WHEEL INSPECTION. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .2.37

FRAME, NUTS, BOLTS, FASTENERS . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.38

WHEEL REMOVAL: FRONT OR REAR . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.38

WHEEL INSTALLATION. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.38

TIRE PRESSURE . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . .2.39

TIRE INSPECTION. .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . ..2.39

2.2

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

Special Tools

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutionsx.com/.

Overview

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.

NOTE: Service and adjustments are critical. 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 riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• 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 crankcase. 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 cause.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized

Polaris dealer.

▶ = SEVERE USE ITEM – If vehicle is subjected to severe use, decrease interval by 50% (Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING: Improperly performing the procedures marked with a ■ could result in component failure and lead to

serious injury or death. Have an authorized Polaris dealer perform these services.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.3

MAINTENANCE

Periodic Maintenance Chart

REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

HOUR-

Steering

■

Front Suspension

▶

Rear Suspension

▶

Tires

▶

ADC Fluid Level

Brake Systems and Fluid

▶

Wheels/Fasteners

Frame Fasteners

Engine Oil Level

▶, E

▶, E Air filter, pre-filter

▶, E

Air Box Sediment Tube

Coolant (if applicable)

Head lamp/tail lamp

▶, E Air filter, main element

Recoil housing (if applicable)

▶, E

Brake Pad Wear 10 H 1 M

Battery

▶ = Perform these procedures more often for vehicles subjected to severe use.

E = Emission Control System Service (California)

■ = Have an authorized Polaris Dealer perform these services.

20 H 1 M

CALEN-

DAR

–

Pre-Ride

Daily

Weekly

MILES (KM)

–

100 (160) Inspect periodically

200 (320)

Make adjustments as needed.

Inspect; clean often

Drain deposits when visible

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

Drain water as needed, check often if operating in wet conditions

Check terminals; clean; test

2.4

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

HOUR-

Engine oil change (break-in

▶, E

period)

Front gearcase fluid

▶

Middle gearcase fluid (if

▶

equipped)

Rear gearcase fluid

▶

Transmission fluid 25 H 1 M

Engine breather filter (if

▶, E

equipped)

▶

General lubrication 50 H 3 M

Shift Linkage

Steering

■

Front Suspension

▶

Rear Suspension

▶

■, E

Throttle Cable/TRS Switch 50 H 6 M

E Air intake ducts 50 H 6 M

Drive belt 50 H 6 M

Cooling system (if applicable)

Engine Oil Change

▶, E

Oil filter change

▶, E

Front gearcase fluid

▶

Middle gearcase fluid

▶

(if equipped)

Rear gearcase fluid

▶

Transmission fluid 100 H 12 M

*** Service Note: Under extreme use, change demand drive fluid every 25 hours. “Extreme Use” is defined as constant ADC operation on hilly or

mountainous terrain, or if ADC is the primary mode of operation.

▶ = Perform these procedures more often for vehicles subjected to severe use.

E = Emission Control System Service (California)

■ = Have an authorized Polaris Dealer perform these services.

25 H 1 M

50 H 6 M

100 H 6 M

100 H 12 M

CALEN-

DAR

MILES (KM)

250 (400) Perform a break-in oil and filter change

250 (400)

250 (400) Initial fluid level inspection

250 (400) Inspect; replace if necessary

500 (800) Lubricate all fittings, pivots, cables, etc.

500 (800) Inspect, lubricate, adjust

500 (800)

500 (800) Inspect; adjust; lubricate; replace if necessary

500 (800) Inspect ducts for proper sealing/air leaks

500 (800) Inspect; adjust; replace as needed

500 (800)

1000 (1600)

1000 (1600) Replace with oil change

1000 (1600) Change fluid; also refer to 25 H interval

1000 (1600) Change fluid

Initial fluid level inspection; change demand drive fluid if exposed to extreme use.***

Lubricate

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 25 hours or after one month of operation

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.5

MAINTENANCE

REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

HOUR-

Oil tank vent hose (if

▶, E

applicable)

Fuel system

■, E

Radiator

▶

(if applicable)

Cooling hoses

▶

(if applicable)

Engine mounts

▶

Exhaust muffler/pipe

Spark Plug

■, E

Ignition Timing

■, E

Wiring

▶

Clutches

■ (drive & driven)

Front wheel bearings

■

Brake fluid 200 H 24 M

■

ADC fluid 200 H 24 M

Spark arrestor

Idle Speed

Toe Adjustment

■

■, ▶ Auxiliary brake

Headlight aim

*** Service Note: Under extreme use, change demand drive fluid every 25 hours. “Extreme Use” is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of operation.

▶ = Perform these procedures more often for vehicles subjected to severe use.

E = Emission Control System Service (California)

■ = Have an authorized Polaris Dealer perform these services.

100 H 12 M

300 H 36 M

CALEN-

DAR

—

MILES (KM)

1000 (1600) Inspect routing, condition

1000 (1600)

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks

1000 (1600) Inspect

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

2000 (3200) Change every two years

3000 (4800)

Check for leaks at tank cap, lines, fuel pump, filter, pump, injectors; replace lines every two years

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Clean out

Adjust as needed

Inspect periodically; adjust when parts are replaced

Inspect daily, adjust as needed

Adjust as needed

2.6

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

MAINTENANCE

PART NO. DESCRIPTION

Engine Lubricant

2870791

2876244

2876245

2202166

2878920

2878919

2879004

2540086

Gearcase / Transmission Lubricants

2878068

2878069

2878070

2876160

2872276

2877922

2877923

2870465

Grease / Specialized Lubricants

2871312 Grease Gun Kit

2871322

2871423

2871460

2871515

2871551

2871329

Coolant

2871323

2871534

Fogging Oil (12 oz. Aerosol)

PS-4 Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Synthetic 4-Cycle Engine Oil (Gallon)

PS-4 Oil Change Kit with Filter

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Gallon)

PS-4 Extreme Duty Oil Change Kit with Filter

Engine Oil Filter

AGL Gearcase Lubricant (1 Qt.) (12 Count)

AGL Gearcase Lubricant (1 Gal.) (4 Count)

AGL Gearcase Lubricant (2.5 Gal.) (2 Count)

ATVAngle Drive Fluid (8 oz.) (12 Count)

ATVAngle Drive Fluid (2.5 Gal) (2 Count)

Demand Drive Fluid (Quart)

Demand Drive Fluid (2.5 Gallon)

Oil Pump for 1 Gallon Jug

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Starter Drive Grease (12 Count)

Premium U-Joint Lube (3 oz.) (24 Count)

Premium U-Joint Lube (14 oz.) (10 Count)

Dielectric Grease (Nyogel™)

60/40 Coolant (Gallon) (6 Count)

60/40 Coolant (Quart) (12 Count)

PART NO. DESCRIPTION

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652

2872189

2871557

Loctite™ Threadlock 242 (6 ml.) (12 count)

Premium Carbon Clean (12 oz.) (12 count)

Fuel Stabilizer (16 oz.) (12 count)

DOT 4 Brake Fluid (12 count)

Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

NOTE: Each item can be purchased separately at your local Polaris dealer.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.7

MAINTENANCE

LUBRICATION / FLUIDS

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check tire condition and air pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation and adjustment (includes auxiliary brake)

• Throttle -check for free operation

• Headlight/Taillight/Brake light - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

Lubrication / Grease Points (4x4)

# ITEM LUBE METHOD

Engine Oil

2. Transmission

Front

Gearcase

4. Brake Fluid

5. Front A-Arm

6. Rear A-Arm

Propshafts

* Perform more often under severe use, such as operation in water and under severe loads.

(A) Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads).

(B) Annually or 100 hours of operation Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads). ADC gearcase fluid should be changed every 25hrs of operation in extreme use conditions (i.e. continuous operation on hilly or mountainous terrain or if ADC ‘on’ is primary mode of AWD operation).

(C) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special.

Polaris PS-4

Polaris AGL Synthetic Gearcase Lube

Demand Drive Fluid

Polaris DOT 4 Brake Fluid

Polaris All Season Grease

Polaris U-Joint Grease

(C)

Check dipstick and add to proper level.

Add lube to bottom fill hole.

Drain as directed. Add specified quantity.

Fill master cylinder reservoir to indicated level

Locate fitting and grease. Semi-annually (A)

Locate fitting and grease Semi-annually (A)

Locate fitting and grease. Semi-annually (A)

FREQUENCY*

Change after 1st month, then 6 months or 100 hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually (B)

Gearcase - Change annually (B)

As required, change fluid every 2 years

2.8

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Lubrication / Grease Points (6x6)

MAINTENANCE

# ITEM FLUID METHOD

Engine Oil

Transmission

Front

3A.

Gearcase /

3B.

ADC Fluid Middle and

Rear

4. Gearcases

5. Brake Fluid

6. Front A-Arm

7. Rear A-Arm

Front

8. Propshaft

* Perform more often under severe use, such as operation in water and under severe loads.

(A) Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads).

(C) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special.

Polaris PS4 2W/50

Polaris AGL Synthetic Gearcase Lube

Demand Drive Fluid

ATVAngle Drive Fluid

Polaris DOT 4 Brake Fluid

Polaris All Season Grease

Polaris U-Joint Grease

(C)

Check dipstick and add to proper level.

Add lube to bottom fill hole.

Drain as directed. Add specified quantity.

Drain completely. Add lube to specified quantity.

Fill master cylinder reservoir to indicated level

Locate fitting and grease. Semi-annually (A)

Locate fitting and grease Semi-annually (A)

Locate fitting and grease. Semi-annually (A)

FREQUENCY*

Change after 1st month, then 6 months or 100 hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually (B)

Gearcase - Change annually / 25hrs ADC Reservoir - Change every 200 hours

Change annually (B)

As required, change fluid every 2 years

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.9

MAINTENANCE

Engine Oil Level

The 800 EFI twin engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level:

1. Park machine on a level surface and set the parking brake.

2. Stop the engine. Allow the oil level to settle for 3 minutes before removing the dipstick.

NOTE: Do not check oil immediately after engine operation.

3. For easier access, remove the seat the RH side panel.

5. Reinstall dipstick and push it into place. Do not lock the dipstick.

NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of stick consistent. When reinstalling the dipstick, make certain to seat the lever lock.

6. Remove dipstick (C) and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill. (See NOTE below!)

NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper side of the dipstick as it is being removed, regardless of the level marks being on top or on bottom. (See illustration)

4. Unlock the lever lock (A). Remove dipstick (B) and wipe dry with a clean cloth.

2.10

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

MAINTENANCE

Oil/Filter Change

1. Park vehicle on a level surface.

2. Run engine two to three minutes until warm. Stop engine.

3. Clean area around drain plug at bottom of engine.

4. Place a drain pan beneath crankcase and remove drain plug.

CAUTION

Do not allow hot oil to come into contact

with your skin, as serious burns may result.

5. Allow oil to drain completely.

6. Replace the sealing washer on drain plug.

NOTE: The sealing surfaces on drain plug and oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to specification.

Drain Plug:

15 ft-lbs (22 Nm)

8. Place shop towels beneath oil filter (A). Using Oil Filter Wrench PU-50105, turn filter counterclockwise to remove.

10. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of recommended engine oil.

Recommended Engine Oil:

PS-4 Synthetic (PN 2876244)

Ambient Temp Range: -35° F to 100° F

PS-4 Extreme Duty Synthetic (PN 2878920)

Ambient Temp Range: 0° F to 120° F

Capacity: 2 Quarts (1.9 L)

Oil Filter (PN 2540086)

13. Place gear selector in park and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

9. Using a clean dry cloth, clean filter sealing surface on crankcase.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.11

MAINTENANCE

Front Gearcase Lubrication (4x4)

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

• The correct front gearcase lubricant to use is Polaris Demand Drive Hub Fluid.

To Change Gearcase Lubricant:

1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque to specification.

Specified Lubricant:

Demand Drive Hub Fluid

Gearcase Capacity: 8.97oz. (265 ml.)

Fill Plug: 8-30 ft-lbs (11-40 Nm)

Drain Plug: 8-30 ft-lbs (11-40 Nm)

To Check the Lubricant Level:

Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page.

2.12

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3. Remove fill plug (C). Inspect the O-ring.

4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

5. Install / torque fill plug and check for leaks.

MAINTENANCE

Front Gearcase Lubrication (6x6)

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

• The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.

To Change Gearcase Lubricant:

1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new O-ring if needed. Torque to specification.

3. Remove fill plug. Inspect the O-ring.

4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

Specified Lubricant:

Demand Drive Hub Fluid

ADC Gearcase Capacity:

9.3 oz. (275ml.)

ADC GEARCASE SERVICE NOTE:

Under extreme use, change fluid every 25

hours. "Extreme Use" is defined as constant

ADC operation on hilly or mountainous terrain,

or if ADC is the primary mode of operation.

Fill Plug: 8-30 ft-lbs (11-40 Nm)

Drain Plug: 8-30 ft-lbs (11-40 Nm)

To Check the Lubricant Level:

Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

5. Install / torque fill plug and check for leaks.

2.13

MAINTENANCE

ADC Differential Hydraulic Circuit Fluid Change (6x6)

Service Note: Under extreme use, change ADC fluid

every 25 hours. “Extreme Use” is defined as constant ADC operation on hilly or mountainous terrain, or if ADC ‘on’ is the primary mode of AWD operation.

1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit.

2. Thoroughly clean area around and on remote reservoir and bleeder valves.

3. Remove reservoir cap and diaphragm assembly.

4. Make sure fluid inside reservoir is free of debris. If any debris is found, use a clean rag or suction device to remove from the reservoir.

7. Turn bleeder valves counter-clockwise to loosen. Loosen bleeder screw slowly, allowing oil and any trapped air to flow out of fitting.

NOTE: Do not allow hydraulic fluid in reservoir to drain below minimum fill line. Close bleeder valves before oil level falls below minimum fill line. Refilling empty reservoir may result in air pockets becoming trapped.

If an empty reservoir is encountered, filling of fluid is still possible. Verify air bubbles are not trapped in the reservoir line before proceeding with step 7.

8. Continue steps 6-8 on both sides in sequence until clean fluid is seen when bleeding occurs.

9. Re-torque both bleeder valves to specification and reinstall cover caps.

Bleeder Valve:

80 in-lbs (9 Nm)

10. Fill reservoir with Demand Drive to a level midway between ‘MAX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir.

11. Replace reservoir cap securely and wipe clean any residue.

WARNING

Debris in reservoir may block porting and produce

inadequate bleeding of the system. Decreased

performance may be encountered with inadequate

5. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Demand Drive fluid.

6. Locate bleeder valves found on either side of differential and remove the protective caps.

bleed of the hydraulic circuit.

2.14

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

Transmission Lubrication (4x4)

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level and in Park before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

• Follow instructions to check/change transmission lubricant.

To Change Lubricant:

1. Remove transmission drain plug (B) to drain the oil. Discard used oil properly.

2. Clean and reinstall the drain plug. Torque to specification.

Transmission Drain Plug:

14 ft-lbs (19 Nm)

Transmission Check/Fill Plug:

14 ft-lbs (19 Nm)

To Check the Fluid Level:

Remove check / fill plug (A) from the left side of transmission and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole threads.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3. Remove fill plug.

4. Add the correct amount of Polaris AGL Gearcase Lubricant.

Transmission - Specified Lubricant:

Polaris AGL Gearcase Lubricant

(Gallon - PN 2878069) (1qt. - PN 2878068)

Capacity: 33.8 oz. (1000 ml)

5. Check for leaks.

6. Install fill plug. Torque to specification.

Transmission Check/Fill Plug:

14 ft-lbs (19 Nm)

2.15

MAINTENANCE

Transmission Lubrication (6x6)

The (transmission) lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level and in Park before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

• Follow instructions to check / change transmission lubricant.

To Change Lubricant:

1. Remove transmission drain plug (B) to drain the oil. Discard used oil properly.

2. Clean and reinstall the drain plug (B). Torque to specification.

3. Remove fill plug (A).

4. Add the correct amount of Polaris AGL Gearcase Lubricant.

5. Check for leaks.

6. Install fill plug (A). Torque to specification.

Transmission - Specified Lubricant:

Polaris AGL Gearcase Lubricant

(Gallon - 2878068) (Quart. - PN 2878069)

Sportsman 6x6 - Capacity: 17.2 oz. (510 ml)

Transmission Drain / Fill Plug:

14 ft-lbs (19 Nm)

To Check the Fluid Level:

Remove fill plug (A) from the back of the transmission and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole as shown at below.

2.16

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

Middle Gearcase Lubrication (6x6)

The middle gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

To Change Gearcase Lubricant:

1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new sealing ring (B). Torque to specification.

3. Remove fill plug. Inspect the o-ring and replace if necessary.

4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads.

5. Install / torque fill plug and check for leaks.

Specified Lubricant:

Polaris Angle Drive Fluid (ADF)

Gearcase Capacity:

13.5 oz. (400 ml.)

Fill Plug: 15 ft-lbs (20 Nm)

Drain Plug: 15 ft-lbs (20 Nm)

To Check the Lubricant Level:

Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.17

MAINTENANCE

Rear Gearcase Lubrication (6x6)

The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

Specified Lubricant:

Polaris Angle Drive Fluid

Gearcase Capacity: 5.0 oz. (150 ml.) Fill to bottom of

check / fill plug hole threads.

Fill Plug: 9 ft-lbs (12 Nm)

Drain Plug: 11 ft-lbs (15 Nm)

To Check the Lubricant Level:

Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page.

To Change Gearcase Lubricant:

1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque to specification.

3. Remove fill plug. Inspect the o-ring and replace if necessary.

4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

2.18

5. Install / torque fill plug and check for leaks.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

VEHICLE INSPECTION

MAINTENANCE

Shift Link Rod Inspection (4x4)

NOTE: Shift rod is preset at time of manufacturer.

1. Lubricate pivot points with a light aerosol lubricant or grease if desired.

Shift Link Rod Inspection (6x6)

NOTE: Shift rod is preset at time of manufacturer.

1. Inspect shift link tie rod ends and replace if worn or damaged. Lubricate pivot points with a light aerosol lubricant or grease if desired.

Throttle Inspection

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.

2. Place shift selector in neutral and set parking brake.

3. Loosen lock nut on in-line cable adjuster (Ill. 1).

4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. Adjust cable tension as needed until lock-to-lock turning can be accomplished with no rise in engine rpm.

5. Replace the throttle cable if worn, kinked, or damaged.

To Remove TRS Cover:

6. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.

7. Twist screwdriver slightly while lifting on the cover to release snap.

8. Repeat procedure at the other five locations as shown.

NOTE: Do not attempt to remove cover until all latch points are released.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.19

MAINTENANCE

Throttle Cable / Throttle Release System (TRS Switch) Adjustment

1. Slide boot (A) off throttle cable adjuster and jam nut.

2. Place shift selector in neutral and set parking brake.

3. Loosen lock nut (B) on in-line cable adjuster (Ill. 1).

4. Turn adjuster (C) until specified freeplay is achieved at thumb lever. (see illustration). After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.

Fuel System

WARNING

* Gasoline is extremely flammable and explosive under

certain conditions.

* EFI components are under high pressure. Verify

system pressure has been relieved before disassembly.

* Never drain the fuel system when the engine is hot.

Severe burns may result.

* Do not overfill the tank. The tank is at full capacity

when the fuel reaches the bottom of the filler neck.

Leave room for expansion of fuel.

* Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous

and can cause loss of consciousness and death in a

short time.

* Do not smoke or allow open flames or sparks in or

near the area where refueling is performed or where

gasoline is stored.

* If you get gasoline in your eyes or if you should

swallow gasoline, seek medical attention immediately.

0.0625 - 0.1250" (1.58 - 3.17mm)

Throttle Freeplay:

5. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure

* If you spill gasoline on your skin or clothing,

immediately wash with soap and water and change

clothing.

* Always stop the engine and refuel outdoors or in a

well ventilated area. Keep away from open flames and

electrical components when removing fuel filter.

Vent Lines

Check fuel tank, oil tank, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace Be sure vent lines are routed properly and secured with cable ties.

CAUTION

Verify vent lines are not kinked or damaged.

2.20

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

MAINTENANCE

Compression Test

IMPORTANT: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 150200 psi during a compression test.

A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn, damaged exhaust cam lobes. Inspect camshaft and combustion chamber if compression is abnormally high.

A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak).

Cylinder Compression

Standard: 150-200 PSI

Cylinder Leakdown

Service Limit 15%

(Inspect for cause if test exceeds 15%)

Engine Mounts

Inspect rubber engine mounts (A) for cracks or damage.

Check engine fasteners and mounts, ensure they are tight.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.21

MAINTENANCE

Spark Plug

1. Clean plug area so no dirt and debris can fall into engine when plug is removed. Remove spark plug high tension lead.

2. Remove spark plug.

3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only.

CAUTION

6. If necessary, replace spark plug with proper type.

WARNING

Severe engine damage may occur if the incorrect spark

plug is used.

7. Apply a small amount of anti-seize compound to the spark plug threads.

8. Install spark plug and torque to specification.

Spark Plug:

18 ft-lbs (24 Nm)

A wire brush or coated abrasive should not

be used for cleaning spark plugs.

5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.

2.22

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Battery Maintenance

Complete battery servicing information for both conventional and sealed batteries can be found in Chapter 10 of this manual.

MAINTENANCE

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds and

other chemicals known to the State of California to

cause cancer, birth defects, or other reproductive harm.

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

a 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.

NOTE: Expected battery shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

New Batteries: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery's rated amp/ hour capacity. Do not use the alternator to charge a new battery. (Refer to battery video PN 9917987).

(Conventional Battery Only) Inspect the battery fluid level. When the electrolyte nears the lower level, remove the battery and add distilled water only to the upper level line.

To Remove the Battery:

1. Disconnect holder strap and remove cover.

2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

WARNING

To reduce the chance of sparks: Whenever removing

the battery, disconnect the negative (black) cable first.

When reinstalling the battery, install the negative cable

last.

3. Disconnect the vent hose.

4. Remove the battery.

5. (Conventional Battery Only) Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery.

NOTE: Use only distilled water. Tap water contains minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to enter a battery, as it will shorten the life of the battery.

6. Fully recharge the battery.

7. Reinstall battery caps (Conventional Battery Only).

8. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly.

9. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable.

10. Reattach vent hose making sure it is properly routed and not kinked or pinched.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

2.23

MAINTENANCE

11. Coat terminals and bolt threads with Dielectric Grease (PN 2871329).

12. Reinstall battery cover and holder strap.

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

• Some coolant level drop on new machines is

normal as the system is purging itself of trapped air. Observe coolant levels often during the breakin period.

• Overheating of engine could occur if air is not fully

purged from system.

• Polaris Premium 60/40 anti-freeze is premixed and

ready to use. Do not dilute with water.

Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer.

Cooling Hoses

Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or

straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system

to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze/ Coolant

(PN 2871323)

2.24

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

1. Check tightness of all hose clamps.

2. Do not over-tighten hose clamps at radiator or radiator fitting may distort, causing a restriction or leak.

Radiator

1. Check radiator external air flow passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

Cooling System Pressure Test

See Chapter 3 for pressure test procedures.

MAINTENANCE

Reservoir Level Inspection

WARNING

Never remove the radiator pressure cap when the

engine is warm or hot. Escaping steam and fluid can

cause severe burns. The engine must be allowed to

cool before removing the pressure cap.

Remove any obstructions with compressed air or low pressure water.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If it is not:

1. Remove reservoir cap. Verify the vent is clear and open.

2. Fill reservoir (A) to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

IMPORTANT: If overheating is evident, allow system to cool completely and check coolant level in the radiator. Inspect for signs of trapped air in system.

Radiator Coolant Level

WARNING

Never remove the radiator pressure cap when the

engine is warm or hot. Escaping steam and fluid can

cause severe burns. The engine must be allowed to

cool before removing the pressure cap.

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected via the radiator cap first and coolant added if necessary.

Use of a non-standard pressure cap will not allow the recovery system to function properly.

To Access the Radiator Pressure Cap and add fluid:

1. Open the front rack storage area.

2. Remove the (4) T-25 screws securing the access cover to the front cab as shown below.

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MAINTENANCE

3. Move the seal out of the sealing channel and pull up on the front of the access cover. Remove the access cover.

4. The pressure cap is now accessible.

Radiator/Grill Screen

1. Check radiator air passages for restrictions or damage. Check and clean the radiator grille if needed.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

5. Remove the pressure cap and inspect fluid level. Using a funnel, add coolant until the fluid level is to the top of the filler neck.

6. Reinstall the pressure cap and install the front access cover.

2.26

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MAINTENANCE

Air Filter/Pre-Filter Service

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.

The pre filter should be inspected before each ride, and if required, cleaned using the following procedure:

1. lift the seat lock lever and lift up on the rear of the seat.

2. Pull the seat back and free of the tabs.

NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.

3. Remove (6) clips (A) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

7. Inspect element for tears or damage.

8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation:

9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.

10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.

IMPORTANT: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling.

4. Loosen clamp and remove air filter assembly.

Cleaning:

5. Slip the pre-filter element off of main element. Clean the pre filter with hot, soapy water.

6. Rinse and dry thoroughly.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.

11. Install air box cover and secure with the (6) clips.

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MAINTENANCE

Air Box Sediment Tube

Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube.

1. Remove drain plug (A) from end of sediment tube (B).

2. Drain tube.

3. Reinstall drain plug.

NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

Engine Breather Hose

Four-cycle ATV engines are equipped with a engine breather hose (C). The breather line is located on top of the cylinder head cover, below the gas tank. Be sure breather line is routed properly and secured in place. Make sure the line is not kinked or pinched.

2.28

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PVT Inspection / Drying Procedure

IMPORTANT: If operating the ATV in or through water, be sure to check the PVT cover and other components for water ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the PVT cover, simply remove the PVT drain plug and O-ring (A) located on the bottom of the PVT cover and let the water drain out. The PVT drain plug is shown below.

Engine Ground

Inspect engine-to-frame ground cable connection (D). Be sure the connection clean and tight.

2. To further expel water from the cover and to dry out the PVT system, shift the transmission to neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches. Allow engine RPM to settle to idle speed, shift transmission to lowest available range and test for belt slippage. Operate ATV in lowest available range for a short period of time until PVT system is dry.

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Camber/Caster

Camber and caster are non-adjustable.

Steering Inspection

WARNING

Due to the critical nature of the procedures outlined in

this chapter, Polaris recommends steering component

repair and adjustment be performed by an authorized Polaris MSD-certified technician when replacing worn

or damaged steering parts. Use only genuine Polaris

replacement parts.

The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always use new cotter pins.

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to following pages for procedure.

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Tie Rod / Steering

• To check for play in the tie rod end, grasp the

steering tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end on steering

post.

• Replace any worn steering components. Steering

should move freely through entire range of travel without binding.

• Elevate front end of machine so front wheels are

off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (possible loose wheel nuts or loose front hub components).

NOTE: Properly raise and support vehicle to check the front steering and suspension.

• Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures.

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Wheel Alignment

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and secure handlebars in this position.

3. Place a chalk mark on the center line of the front tires approximately 10" (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

4. Measure the distance between the marks and record the measurement. Call this measurement “A”.

5. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle centerline.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8" to 1/4" (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8" to 1/4" (.3 to .6 cm) wider than the measurement at the rear (B).

Toe Alignment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure handlebars are straight ahead before determining which tie rod (s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that the

following precautions be taken when tightening tie rod

end jam nuts. If the rod end is positioned incorrectly it

will not pivot, and may break.

To Adjust Toe Alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified.

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. See illustration.

• After alignment is complete, torque jam nuts to specification.

2.32

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

Wheel Toe-Out:

Tie Rod Jam Nut:

13 ft-lbs (18 Nm)

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MAINTENANCE

Exhaust Pipe

The exhaust pipe must be periodically purged of accumulated carbon as follows:

WARNING

* Do not perform clean-out immediately after the engine

has been run, as the exhaust system becomes very

hot. Serious burns could result from contact with hot

exhaust components.

* To reduce fire hazard, make sure that there are no

combustible materials in the area when purging the

spark arrestor.

* Wear eye protection.

* Do not stand behind or in front of the vehicle while

purging the carbon from the spark arrestor. Never run

the engine in an enclosed area.

* Exhaust contains poisonous carbon monoxide gas.

* Do not go under the machine while it is inclined. Set

the hand brake and block the wheels to prevent roll

back.

Failure to heed these warnings could result in serious

personal injury or death.

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3. See ‘WARNING’.

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3. See ‘WARNING’.

1. Remove the clean out plugs located on the bottom of the muffler as shown

2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

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6. Repeat Steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the clean out plugs.

Brake System Inspection

The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.

• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.

• Use Polaris DOT 4 Brake Fluid

2.34

• Check brake for excessive travel or spongy feel.

• Check brake system for fluid leaks.

• Check friction pads for wear, damage or looseness.

• Check surface condition of the disc.

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Brake Pads

Pads should be changed when the friction material is worn beyond the service limit.

Brake Pad Service Limit:

.180" (4.6 mm)

Brake Hose Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

Auxiliary Brake Testing

The auxiliary brake should be checked for proper function.

1. Support the rear wheels off the ground.

2. While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest.

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Auxiliary Brake Adjustment

Use the following procedure to inspect the hydraulic auxiliary (foot) brake system and adjust or bleed if necessary:

First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

If less than one inch, two things must be examined:

Free Play:

Suspension: Spring Preload Adjustment

Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary. Use Shock Spanner Wrench (PN 2870872) to adjust the rear springs.

Front Suspension

• Compress and release front suspension. Dampening should be smooth throughout the range of travel.

• Check all front suspension components for wear or damage.

• Inspect front strut cartridges for leakage.

Rear Suspension

• Compress and release rear suspension. Dampening should be smooth throughout the range of travel.

• Check all rear suspension components for wear or damage.

• Inspect shock for leakage.

Foot Brake Freeplay:

1/8 - 1/4 inch (3.2 - 6.35 mm)

If free play is excessive, inspect pedal, linkage, and master cylinder for wear or damage and replace any parts as needed.

Bleeding:

If free play is correct and brake pedal travel is still excessive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9.

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CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have your Polaris dealer replace the boot.

ATV Controls

Check controls for proper operation, positioning and adjustment.

Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.

Wheel Inspection

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

ITEM Steel - Front and Rear

Wheel Nuts

Aluminum - Front and Rear

Wheel Nuts

Front Hub Retaining Nut

Rear Hub Retaining Nut

SPECIFICATION

27 ft-lbs (37 Nm)

30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn)

60 ft-lbs (81 Nm)

80 ft-lbs (108 Nm)

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Frame, Nuts, Bolts, Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

Wheel Removal: Front Or Rear

1. Stop the engine, place the transmission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

Wheel Installation

1. With the transmission in park and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque listed in the table

CAUTION

Improperly installed wheels could affect vehicle

handling and tire wear. On vehicles with tapered rear

wheel nuts, make sure tapered end of nut goes into

taper on wheel. Torque to proper specification.

4. Remove the wheel nuts and remove the wheel.

2.38

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ITEM Steel - Front and Rear

Wheel Nuts

Aluminum - Front and Rear Wheel Nuts

Front Hub Retaining Nut

Rear Hub Retaining Nut

SPECIFICATION

27 ft-lbs (37 Nm)

30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn)

60 ft-lbs (81 Nm)

80 ft-lbs (108 Nm)

MAINTENANCE

Tire Pressure

CAUTION

Maintain proper tire pressure. Refer to the warning tire

pressure decal applied to the vehicle.

TIRE PRESSURE INSPECTION (PSI - COLD) 4X4

Front Rear 5 (34.5 Kpa) 5 (34.5 Kpa)

TIRE PRESSURE INSPECTION (PSI - COLD) 6X6

Front Rear 7 (48.25 Kpa) 10 (69 Kpa)

Tire Inspection

• Improper tire inflation may affect ATV maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect ATV handling.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8, (3 mm) or less.

WARNING

Operating an ATV with worn tires will increase the

possibility of the vehicle skidding and possible loss of

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/

control.

8inch (.3 cm) or less.

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NOTES

2.40

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ENGINE

CHAPTER 3

ENGINE

SPECIFICATIONS . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . . 3.3

CRANKCASE EXPLODED VIEWS .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . 3.3

ENGINE FASTENER TORQUE PATTERNS . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.10

TORQUE SPECIFICATIONS . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. .. 3.11

800 EFI ENGINE SERVICE SPECIFICATIONS .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . 3.12

GENERAL ENGINE SERVICE .. . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .3.16

ACCESSIBLE COMPONENTS .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . .3.16

PISTON IDENTIFICATION .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..3.16

COOLING SYSTEM SPECIFICATIONS. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.16

COOLING SYSTEM PRESSURE TEST.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..3.17

COOLANT AIR BLEEDING PROCEDURE .. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.17

ENGINE REMOVAL (TYPICAL) . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .3.18

ENGINE INSTALLATION NOTES . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . .3.19

CYLINDER HONE SELECTION AND HONING PROCEDURE .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . .3.20

HONING TO DEGLAZE . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .3.21

CLEANING THE CYLINDER AFTER HONING . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . .3.21

OIL FLOW CHART . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . ..3.22

ENGINE LUBRICATION SPECIFICATIONS. . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.23

OIL PRESSURE TEST .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.23

ENGINE DISASSEMBLY AND INSPECTION . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.24

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . .3.24

ROCKER ARMS . . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .3.25

PUSH RODS. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.25

CYLINDER HEAD REMOVAL . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .3.26

CYLINDER HEAD INSPECTION . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .3.26

CYLINDER HEAD WARP. . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . .3.26

VALVE SEAL/SPRING SERVICE (ON ENGINE) . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . 3.27

CYLINDER HEAD DISASSEMBLY .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .3.27

VALVE INSPECTION. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. .. . . . .. ..3.29

COMBUSTION CHAMBER . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.30

VALVE SEAT RECONDITIONING . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.30

CYLINDER HEAD REASSEMBLY .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..3.33

VALVE SEALING TEST . . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .3.34

CYLINDER REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . 3.34

VALVE LIFTER REMOVAL/INSPECTION. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.35

PISTON REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .3.36

CYLINDER INSPECTION . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.37

PISTON-TO-CYLINDER CLEARANCE . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.38

PISTON/ROD INSPECTION. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..3.39

PISTON RING INSTALLED GAP . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . .3.39

STARTER DRIVE/BENDIX REMOVAL INSPECTION . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .3.40

FLYWHEEL / STATOR REMOVAL / INSPECTION. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..3.41

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3.1

ENGINE

ENGINE REASSEMBLY . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . ..3.53

800 EFI EXHAUST SYSTEM . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .3.71

TROUBLESHOOTING . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.72

ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .3.42

CAMSHAFT INSPECTION . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .3.51

CRANKCASE REASSEMBLY .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .3.53

FLYWHEEL / STATOR INSTALLATION .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.66

CYLINDER HEAD INSTALLATION.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . .3.67

EXHAUST LAYOUT . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.71

ENGINE . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . ..3.72

COOLING SYSTEM . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.73

3.2

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

SPECIFICATIONS

Crankcase Exploded Views

ENGINE

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.3

ENGINE

Oil / Water Pump and Timing Cover Exploded View

3.4

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Starter / Flywheel / Water Pump Exploded View

ENGINE

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.5

ENGINE

Oil System / Level Assembly Exploded View

3.6

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Cylinder / Cylinder Head Exploded View

ENGINE

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.7

ENGINE

Engine Sensors & Misc. Exploded View

3.8

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

EFI Harness Exploded View

ENGINE

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.9

ENGINE

Engine Fastener Torque Patterns

3.10

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Torque Specifications

ENGINE

Engine Torque Specifications

FASTENER SIZE

Camshaft Gear 8 mm

Camshaft Thrust Plate 6 mm Carburetor Adaptor Bolts

Counterbalance Gear 8 mm

Crankcase Bolts 8 mm

Crankcase Breather Cylinder Head Bolts

Exhaust Manifold 8 mm Flywheel

Injector Rail

Magneto Cover

Oil Baffle Weldment Oil Drain Bolt (Crankcase)

Oil Fill Tube Bolt Oil Filter Pipe Fitting

Oil Pick Up

Oil Pressure Relief Plug

Oil Pump Housing Screw

Rocker Arm 8 mm

Rocker Cover 6 mm Spark Plug

Starter Motor 6 mm Stator Assembly

Stator Hold Down Bracket 6 mm Stator Housing

Temperature Switch

Thermostat Housing

Timing Plug

Stator Wire Holddown Water Pump Housing Cover

Water Pump Impeller Nut

8 mm

5 mm

11 mm

14 mm

8 mm

6 mm

5 mm

12 mm

5 mm

20 mm

5 mm

10 mm

6 mm

14 mm

6 mm

3/8 NPT

6 mm

3/4-16

5 mm

6 mm

8 mm

IN-LBS (NM) FT-LBS (NM)

- 22 ± 2 (30 ± 3)

115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35)

216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7)

- 22 ± 2 (30 ± 3)

- * 22 ± 2 (30 ± 3)

20 ± 5 (2.5 ± 0.55) -

See Exploded View See Exploded View

216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

- 65 ± 7 (88 ± 9.50)

216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

* 96 ± 3 (10.85 ± 0.35) -

60 ± 6 (6.8 ± 0.68) -

192 ± 24 (21.7 ± 2.7) 16 ± (21.7)

50 ± 5 (5.64 ± 0.56) -

- 35 ± 4 (47.5 ± 5.4)

60 ± 6 (6.8 ± 0.68) -

22 ± 2 (30 ± 3) -

* 84 ± 8 (9.50 ± 0.90) -

- * 22 ± 2 (30 ± 3)

* 84 ± 8 (9.5 ± 0.9) -

216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7)

* 84 ± 8 (9.5 ± 0.9) -

96 ± 3 (10.85 ± 0.35) -

- 8 ± 1 (11.05 ± 1.15)

* 96 ± 3 (10.85 ± 0.35) -

- 25 ± 3 (34 ± 4)

84 ± 8 (9.5 ± 0.9) -

- 7-9 (10-12 Nm)

* 96 ± 3 (10.85 ± 0.35) -

108 ± 3 (12 ± 0.35) -

NOTE: * See exploded views for notes or torque sequences.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.11

ENGINE

800 EFI Engine Service Specifications

Engine Specifications

MAIN COMPONENT: CYLINDER HEAD EH076OLE

Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm)

Camshaft Journal Outer Diameter - Mag 1.654" ± 0.00039" (42 ± 0.010 mm)

1.634"± 0.00039" (41.50 ± 0.010 mm)

1.614" ± 0.00039" (41 ± 0.010 mm)

1.637" ± 0.00039" (41.58 ± 0.010 mm)

1.617" ± 0.00039" (41.07 ± 0.010 mm)

0.00276" ± 0.00079" (0.07 ± 0.02 mm)

0.0472" ± 0.00787" - 0.0039" (1.20 ± 0.20 - 0.10mm)

0.0591" ± 0.00787" - 0.0039" (1.50 ± 0.20 - 0.10 mm)

45.5° ± 0.255°

0.2367" ± 0.00029" (6.012 ± 0.007 mm)

0.807" ± 0.0039" (20.50 ± 0.01 mm)

Standard: 0.79" (20.06 mm) Max- 0.98" (24.89 mm) Min- 0.59" (14.98 mm)

Standard: 0.80" (20.32 mm) Max- 1.0" (25.4 mm) Min- 0.60" (15.24 mm)

0.2356" ± 0.00039" (5.985 ± 0.01 mm)

0.2351" ± 0.00039" (5.972 ± 0.01 mm)

0.00228" ± 0.00098" (0.058 ± 0.025 mm)

0.00275" ± 0.00098" (0.0870 ± 0.025mm)

Intake - 1.4638" (37.18 mm) Exhaust - 1.4736" (37.43 mm)

Camshaft

Counter Balance

Cylinder Head

Valve Seat

Valve Guide

Valve

Valve Spring

Camshaft Journal Outer Diameter - Center

Camshaft Journal Outer Diameter - PTO Camshaft Journal Bore ID - Mag 1.656" ± 0.00039" (42.07 ± 0.010 mm)

Camshaft Journal Bore ID - Center

Camshaft Journal Bore ID - PTO

Camshaft Oil Clearance Camshaft End Play 0.0167" ± 0.0098" (0.425 ± 0.25 mm)

Counter Balance End Play 0.005" (0.127 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm)

Cylinder Head - Standard height 3.478" (88.35 mm)

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle

Valve Guide Inner diameter

Valve Guide Protrusion Above Head

Valve Margin Thickness - Intake

Valve Margin Thickness - Exhaust

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust Valve Stem Overall Length - Intake 4.51" ± 0.01476" (114.5550 ± 0.375 mm)

Valve Stem Overall Length - Exhaust 4.5453" ± .01496" (115.45 ± 0.38 mm)

Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring Overall Length - Installed Height

3.12

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Engine Specifications

MAIN COMPONENTS: CYLINDER/PISTON/ CONNECTING ROD EH076OLE

Cylinder

Lifter

Piston

Piston Pin

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm)

Cylinder Taper Limit 0.00031" (0.008 mm)

Cylinder Out of Round Limit 0.00030" (0.0075 mm)

Cylinder to Piston Clearance .0015" ± .00059"

Lifter Outer Diameter Standard

Lifter Block Bore 0.8438" ± 0.00062"

Piston - Standard

Piston Standard Inner Diameter of Piston Pin Bore

Piston Pin Outer Diameter

Piston Pin - Standard Clearance Piston Pin to Pin Bore

Piston Pin - Degree of Fit Piston pin must be a push fit (by

0.004" (0.10 mm)

(.040 ± .015mm)

0.84245" ± 0.00025" (21.39 8 ± 0.00635 mm)

(21.4322 ± 0.0157 mm)

3.14803" + .00028" (79.960 + .007 mm)

0.70902" ± .00012" (18.009 ± 0.003 mm)

0.70866" - 0.70846" (18 - 17.995 mm)

0.00047" ± 0.00024" (0.012 ± 0.006 mm)

hand) at 68° F (20° C)

ENGINE

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.13

ENGINE

Engine Specifications

MAIN COMPONENTS: PISTON/ CONNECTING ROD EH076OLE

Top Ring - Standard

Top Ring - Limit

Installed Gap

Piston Ring

Ring to Groove Clearance

Connecting Rod Small End I.D.

Connecting Rod Small End

Connecting Rod

Crankshaft Crankshaft Runout Limit

Radial Clearance

Connecting Rod Big End Side Clearance

Connecting Rod Big End Radial Clearance

Second Ring - Standard

Second Ring - Limit

Oil Ring - Standard

Oil Ring - Limit

Top Ring - Standard

Top Ring - Limit

Second Ring - Standard

Second Ring - Limit

0.0059 ± .0138" (0.15 ± 0.35mm)

> 15% Leakdown

0.0098 ± .0197" (0.25 ± 0.50mm)

> 15% Leakdown

0.0196± 0.00984" (0.50 ± 0.25mm)

> 15% Leakdown

0.0024" ± 0.0008" (0.060 ± 0.020 mm)

> 15% Leakdown

0.0028" ± 0.0008" (0.070 ± 0.020 mm)

> 15% Leakdown

0.7096" - 0.70846" (18 - 17.995 mm)

0.0098"± 0.00039" (0.025 ± 0.010mm)

0.01181"± 0.00591" (0.030 ± 0.015 mm)

0.0015"± 0.00006" (0.0038 ± 0.0015mm)

0.00236" (0.060mm)

3.14

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ENGINE

Special Tools

PART NUMBER TOOL DESCRIPTION

PV-43527 OIL FILTER WRENCH 2200634 VALVE SEAT RECONDITIONING KIT PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER PU-45543 UNIVERSAL DRIVER HANDLE PA-45483 MAIN SEAL INSTALLER PU-45658 CRANKSHAFT MAIN SEAL SAVER PA-45401 WATER PUMP SEAL SAVER 2870975 MITY VAC® PRESSURE TEST TOOL PU-45778 OIL SYSTEM PRIMING TOOL

Bosch Automotive Service Solutions: 1-800-345-2233 or polaris.service-solutions.com

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.15

ENGINE

GENERAL ENGINE SERVICE

Accessible Components

Following Components can be serviced or removed with the engine installed:

• Flywheel

• Alternator (Stator)

• Starter Motor/Drive

• Cylinder Head

• Cylinder

• Piston/Rings

• Camshaft

• Rocker Arms

• Oil pump/Water Pump/Oil Pump Drive Gear

• Gear Train Components

Following Components Require Engine Removal for service:

• Counterbalance Shaft or Bearings

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

Cooling System Specifications

APPROXIMATE

CONDITION

Hot light ON

Fan Off 296Ω - 316Ω

Fan On 236Ω - 251Ω System

Capacity

Radiator Cap Pressure Relief

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

READING (MIN.-MAX)

178Ω - 190Ω

Refer To Chapter 1 Specifications

13 PSI

TEMPERATURE

215° F (108° C)

180° F (82° C)

195° F (91° C)

Piston Identification

Four stroke engine rings have a rectangular profile. See “PISTON RING INSTALLED GAP” for ring installation. Use the information below to identify pistons and rings.

ENGINE MODEL PISTON DIAMETER

EH076OLE 80 mm

3.16

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ENGINE

Cooling System Pressure Test

WARNING

Never remove filler cap when engine is warm or hot.

The cooling system is under pressure and serious

burns may result. Allow the engine and cooling system

to cool before servicing.

System Pressure Test

1. Remove radiator cap cover located under the storage box access panel. See Chapter 5.

2. Remove recovery bottle hose from coolant filler.

3. Connect a Mity Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.

Filler Cap Pressure Test

4. Remove filler cap and test cap using a commercially available cap tester.

5. The filler cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

Coolant Air Bleeding Procedure

Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.

NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

1. Park machine on a flat surface. Remove filler cap and top off coolant. With the cap removed, start and idle machine for 5-10 minutes until steam is visible in the filler neck area.

2. Stop the engine and let cool for a few minutes or until an air bubble is seen at the filler neck, or there is a dropping of the coolant level indicating that coolant has been pulled into the system.

NOTE: Slowly squeezing the filler neck/coolant return hoses will aid in purging the system of air. Pump the hose using your hand several times. Elevating the rear of the ATV with a floor jack (rear tires 4-6”, off the ground) also aids the purging of air from the system.

3. Repeat Steps 1 and 2 until no more coolant is pulled into the system.

4. To test, install the radiator cap and idle machine until fan comes on. Make sure the fan comes on before the hot light.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.17

ENGINE

Engine Removal (Typical)

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to possible injury or death.

1. Clean work area.

2. Thoroughly clean ATV engine and chassis.

3. Disconnect battery (-) negative cable.

4. Remove the following parts as required:

• Seat

• Left and right side covers (refer to Chapter 5)

• Fuel tank covers

• Fuel tank (refer to Chapter 4)

• Springs from exhaust pipe and remove pipe.

5. Drain coolant and engine oil.

6. Remove air pre-cleaner and duct.

7. Remove airbox.

8. Disconnect the throttle body sensor (C) and T-BAP sensor (D). Remove throttle body (A). Insert a shop towel into the engine intake to prevent dirt from entering the ports.

9. Relieve the fuel pressure in the fuel rail (refer to Chapter 4, “FUEL INJECTION”) for proper procedure. Carefully remove the fuel rail (B) and injectors.

11. Remove the crank position sensor (E) located on the mag cover.

12. Remove the air breather line.

13. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses.

14. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover (F).

10. Disconnect spark plug high tension leads.

3.18

15. When removing starter cables, note and mark ground cable and positive (+) cable mounting angle and locations. Remove cables.

16. Remove transmission linkage rod from gear selector and secure out of the way.

17. Disconnect coolant temperature sensor wire located on the cylinder.

18. Remove engine to chassis ground cable.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ENGINE

19. Remove all engine mount nuts and / or engine mount plates. Remove the frame brace (G) from the front left side of the frame.

20. Remove the engine from the left side of the frame.

Engine Installation Notes

After the engine is installed in the frame, review this checklist and perform all steps that apply:

General Items

1. Install previously removed components using new gaskets, seals, and fasteners where applicable.

2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2 or the Owner's Manual).

PVT System

3. Adjust center distance of drive and driven clutch. (Chapter 6)

4. Adjust clutch offset, alignment, and belt deflection. (Chapter 6)

5. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

6. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.

Exhaust

7. Replace exhaust gaskets. Seal connections with high temp silicone sealant.

8. Check to be sure all springs are in good condition.

Bleed Cooling System

NOTE: This cooling system contains vent lines to help purge trapped air during filling. Bleeding generally should not be necessary.

NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.

21. For engine installation, reverse procedures.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

9. Remove radiator cap and slowly add coolant to the bottom of filler neck.

10. Fill coolant reservoir tank to full mark.

11. Install radiator cap and gently squeeze coolant hoses to force any trapped air out of system.

12. Again, remove radiator cap and slowly add coolant to the bottom of fill neck if needed.

3.19

ENGINE

13. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temperature. After engine is cool, check level in reservoir tank and add coolant if necessary.

NOTE: Should the reservoir tank become empty, it will be necessary to refill at the radiator and repeat the bleeding procedure.

Engine Break-In Period

The break-in period for a Polaris ATV engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Use only Polaris PS4 2W/50 synthetic oil or equivalent.

Never substitute or mix oil brands. Serious engine

damage and voiding of warranty can result.

Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

Cylinder Hone Selection And Honing Procedure

CAUTION

A hone which will straighten as well as remove material

from the cylinder is very important. Using a common

spring loaded glaze breaker for honing is not advised

for nicasil cylinders.

Polaris recommends using a rigid hone or arbor honing

machine. Cylinders may be wet or dry honed depending

upon the hone manufacturer's recommendations.

Wet honing removes more material faster and leaves a

more distinct pattern in the bore.

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.

14. Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

15. Check oil reservoir level indicated on dipstick. Add oil if necessary (Refer to Chapter 2, “Engine Oil Level” ).

16. Drive slowly at first to gradually bring engine up to operating temperature.

17. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

18. Perform regular checks on fluid levels, controls and all important bolt torques. Pull only light loads during initial break in.

19. Pull only light loads during initial break-in.

20. Change break in oil and filter at 20 hours or 200 miles.

3.20

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ENGINE

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:

• Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.

• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2, (1.3 cm) above and below the bore at the end of each stroke.

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed, and to check for correct cross-hatch.

NOTE: Do not allow cylinder to heat up during honing.

• After honing has been completed, inspect cylinder for thinning or peeling.

If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting. Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.

IMPORTANT: Clean the cylinder after honing

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.21

ENGINE

Oil Flow Chart

This chart describes the flow of oil through the engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.

3.22

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Engine Lubrication Specifications

Capacity - Approximately 2 U.S. Quarts (1.9 l)

Oil Type - Polaris PS4 2W/50 Synthetic

ENGINE

Filter Wrench - PV-43527 or equivalent

Oil Pressure Specification -

35-55 PSI @ 5500 RPM, Polaris 2W/50 Synthetic,

Engine at operating temperature.

Oil Pressure Test

1. Remove blind plug/sender from left side of crankcase.

2. Insert a 1/4 NPTF oil pressure gauge adaptor into the crankcase and attach the gauge.

3. Start engine and allow it to reach operating temperature, monitoring gauge indicator.

NOTE: Use only Polaris PS4 2W/50 Synthetic Engine Lubricant.

Oil Pressure at 5500 RPM (Engine Hot):

Maximum: 55 PSI

Minimum: 35 PSI

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.23

ENGINE

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

3.24

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

ENGINE

Rocker Arms

1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.

2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.

CAUTION

Do not attempt to true this surface by grinding.

Push Rods

1. Clean push rods (A) in a suitable solvent. Blow dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is clear in the center of the push rod.

WARNING

Always wear safety glasses when working with

compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.

5. If the push rod (A) is visibly bent, it should be replaced.

3. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.25

ENGINE

Cylinder Head Removal

1. Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose.

2. Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.

3. Remove cylinder head (B) and head gasket (C) from the cylinder (D).

Cylinder Head Warp

1. Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

CAUTION

Use care not to damage sealing surface.

3.26

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

Cylinder Head Warp Limit:

.004" (.1016 mm) max

ENGINE

Valve Seal/Spring Service (On Engine)

NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.

In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.

WARNING

Wear eye protection or a face shield during cylinder

head disassembly and reassembly.

1. Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center (TDC). Install the Valve Pressure Hose (PU-45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.

2. Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers. NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).

Cylinder Head Disassembly

1. Carefully remove the cylinder components. Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.

IMPORTANT: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

9924864 - 2012-2014 SPORTSMAN 800 / 6X6

3.27

ENGINE

2. Measure free length of spring with a Vernier caliper. Compare to specifications. Replace spring if measurement is out of specification.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

3. Remove valve guide seals.

NOTE: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

4. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.

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ENGINE

Valve Inspection

1. Remove all carbon from valves with a soft wire wheel or brush.

2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.

3. Check end of valve stem for flaring, pitting, wear or damage (A).

5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.

Valve Stem Diameter:

Intake: 0.2356" + 0.00039"

(5.985 + 0.01 mm)

Exhaust: 0.2351" + 0.00039"

(5.972 + 0.01 mm)

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves can be refaced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.

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ENGINE

6. Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.

Valve Guide I.D.:

0.23672" + 0.000295"

(6.0617 + 0.0075 mm)

7. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.

Combustion Chamber

1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.

NOTE: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning.

Valve Seat Reconditioning

NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.

The cylinder head valve guides cannot be replaced.

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Wear eye protection or a face shield during cylinder

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder

head must be replaced.

Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit (available commercially). Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

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head disassembly and reassembly.

WARNING

ENGINE

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.

1. Install pilot into valve guide.

4. Inspect the cut area of the seat:

* If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180° and make another light cut.

* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue® paste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valve face (A).

2. Apply cutting oil to valve seat and cutter.

3. Place 46° cutter on the pilot and make a light cut.

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6. Insert valve into guide and tap valve lightly into place a few times.

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ENGINE

7. Remove valve and check where the Prussian Blueä indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.

* If the indicated seat contact is at the top edge of the valve face and contacts the margin area (B) it is too high on the valve face. Use the 30° cutter to lower the valve seat.

* If too low, use the 60° cutter to raise the seat. When contact area is centered on the valve face, measure seat width.

* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

* If the seat is too narrow, widen using the 45° cutter and re-check contact point on the valve face and seat width after each cut.

NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face. (B)

Valve Seat Width:

Intake

Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust

Std: .039I (1.0 mm)

Limit: .071" (1.8 mm)

8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.

NOTE: Lapping is not required with an interference angle valve job.

10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.

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ENGINE

11. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s).

12. Thoroughly clean cylinder head and valves.

Cylinder Head Reassembly

NOTE: Assemble the valves one at a time to maintain proper order.

1. Apply engine oil to valve guides and seats.

2. Coat valve stem with molybdenum disulfide grease or 2W-50 Synthetic oil.

3. Install valve carefully with a rotating motion to avoid damaging valve seal.

4. Valve seals should be installed after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.

5. Dip valve spring and retainer in clean engine oil and install.

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ENGINE

6. Place retainer on spring and install Valve Spring Compressor (PU-45257). Install split keepers with the gap even on both sides.

NOTE: A small magnet can aid in installation of the keepers.

7. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

IMPORTANT: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.

Valve Sealing Test

1. Clean and dry the combustion chamber area (A).

2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

3. Repeat for exhaust valves by pouring fluid into exhaust port.

Cylinder Removal

1. Follow engine disassembly procedures to remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose.

3. Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).

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ENGINE

Valve Lifter Removal/Inspection

1. Remove the valve lifter's by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

2. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint-free cloth.

3. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly.

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to make sure that it has a slight convex.

6. If the bottom surface has worn flat, it may be used with the original camshaft only.

IMPORTANT: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.

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3.35

ENGINE

Piston Removal

1. Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

IMPORTANT: If the pistons are to be reused, reassemble the pistons in the same cylinder and direction from which they were removed.

New pistons are non-directional and can be placed in either cylinder.

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second ring.

5. Remove the oil control ring.

The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston.

To Remove:

A) Remove the top rail first followed by the bottom rail.

B) Remove the expander.

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ENGINE

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing surfaces.

2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.

3. Inspect cylinder for wear, scratches, or damage.

Cylinder Warp: .004" (0.1 mm) Max.

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ENGINE

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/2, up from bottom). Record measurements. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.

Piston-To-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Subtract this measurement from the maximum cylinder measurement obtained in Step 5.

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Cylinder Taper Limit: .002" (9.05mm) Max.

Cylinder Out of Round:

Limit: .002" (.0 mm) Max.

800 Standard Bore Size

(Both Cylinders): 3.1496" (80 mm)

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ENGINE

Piston/rod Inspection

1. Measure piston pin bore.

2. Measure piston pin O. D. Replace piston and/or piston pin if out of tolerance.

4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-togroove clearance exceeds service limits.

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown. (See next page)

3. Measure connecting rod small end ID.

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NOTE: Ring should be installed with the mark facing upward.

2. Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder. REMINDER: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

3.39

ENGINE

3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range.

IMPORTANT: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Starter Drive/Bendix Removal Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

3. Remove starter bendix assembly. Note the thrust washers located on both sides of the bendix.

5. After the bendix is removed, tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase.

6. Inspect gear teeth on starter drive (B). Replace starter drive if gear teeth are cracked, worn, or broken.

7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed.

4. Inspect the thrust washer for wear or damage and replace if necessary.

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Polaris Sportsman 800 EFI 4x4 (2012) Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual