Polaris Sportsman 800 EFI Touring Quadricycle, Sportsman 9921454 User Manual
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Quadricycles
• RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2007 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2008 Sportsman 800 Tourin g Quadricycle Owner’s Manual
P/N 9921454
2
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emission Control Systems . . . . . . . . . . . . . . . 64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3
4
KNOW YOUR VEHICLE
####
VIN
Engine Serial Number
Key Number
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
5
SAFETY
Rider Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.
6
SAFETY
Rider Safety
WARNING
Failure to follow the warnings in this manual can result in serious injury or
death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A
collision or rollover can occur quickly, even during routine maneuvers, if you
fail to take proper precautions.
Read and understand your owner's manual and all warnings before operating
a Polaris Quadricycle.
Safety Training
When you purchased your new Quadricycle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this information on a regular basis.
If you purchased a used Polaris Quadricycle from a party other than a
Polaris dealer, please request free safety training from any authorized
Polaris dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. Never allow anyone under 12 years of
age to ride as a passenger on this 2-up Quadricycle.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a
Quadricycle/trailer combination on public roads is prohibited. See your
Polaris dealer about configuring the vehicle to be certified to tow a
trailer on-road.
Equipment Modifications
The warranty on your Polaris Quadricycle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers and large racks may change vehicle handling. Use only Polaris-approved accessories. Know their function and
effect on the vehicle.
7
SAFETY
Rider Safety
WARNING
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the Quadricycle.
Never operate a Quadricycle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Contact an authorized Polaris
Quadricycle dealer or visit the Polaris
web site at www.polarisindustries.com.
Never permit others to operate the Quadricycle unless they have read and
understand this manual and all product labels, and have completed a certified
safety training course.
Never allow anyone under 16 years
of age to operate this vehicle.
Never allow anyone under 12 years
of age to ride as a passenger on this
2-up Quadricycle.
Never carry more than one
passenger on this 2-up Quadricycle.
8
Rider Safety
Always wear an approved helmet
that fits properly. Wear eye
protection (goggles or face shield),
gloves, boots, long sleeves and long
pants.
Never consume alcohol or drugs
before or while operating a
Quadricycle.
Never operate at excessive speeds.
Travel and turn at speeds
appropriate for the terrain, visibility,
operating conditions and your
experience.
SAFETY
Never attempt jumps or other stunts.
9
SAFETY
Rider Safety
Always inspect your Quadricycle
before each use to verify that it's in
safe operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 43.
Keep both hands on the handlebars.
Keep both feet on the footrests.
A passenger should always be
seated in the passenger seat with
both feet on the footrests and both
hands on the passenger grab handles
at all times. The passenger should
never hold on to the operator.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on
rough, slippery or loose terrain.
Always follow the procedures
outlined in this manual for turning.
See page 47.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
10
SAFETY
>15°
Rider Safety
If a Quadricycle has been involved in
an accident, always have an
authorized Polaris dealer inspect the
entire vehicle for possible damage,
including (but not limited to) brake,
throttle and steering systems.
Always follow the procedures
outlined in this manual for driving on
hills. See page 50. Never operate on
hills too steep for the Quadricycle or
for your abilities. Practice on smaller
hills before attempting larger hills.
Avoid climbing hills steeper than 15°.
Never operate with the differential
unlocked ( ) while operating on a
hill or other irregular terrain. See pages 23 and 31. Always move the 4X4 switch
to ADC 4X4 before ascending or descending a hill.
Always follow the procedures
outlined in this manual for driving
downhill and for braking on hills. See
page 53.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 52.
Never attempt to turn the
Quadricycle around on any hill until
you've mastered (on level ground)
the turning technique outlined in this
manual.
11
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for braking if
you stall or roll backwards while
climbing a hill. Never back down a
hill. See page 54.
Always follow the procedures
outlined in this manual for operating
over obstacles. See page 59.
Always follow the procedures
outlined in this manual for operating
on slippery or loose surfaces. Use
extra caution. Always avoid skidding
or sliding. See page 58.
Always follow the procedures
outlined in this manual for driving
through water. Never drive through
deep or fast-flowing water. See page
56.
12
Rider Safety
Always follow the procedures
outlined in this manual for driving in
reverse. See page 61.
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify a Quadricycle through
improper installation or use of
accessories.
SAFETY
Never exceed the stated load
capacity for your vehicle. Cargo
must be properly distributed and
securely attached. Reduce speed
and follow the instructions in this
manual for carrying cargo or towing.
Allow a greater distance for braking.
13
SAFETY
Rider Safety
Never operate the Quadricycle on a
frozen body of water.
Operating on paved surfaces may
affect the handling and control of the
Quadricycle and could result in loss
of control. Avoid sudden turns or
swift movement of the handlebars.
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before starting the engine. See page 27.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about Quadricycle safety,
contact an authorized Polaris Quadricycle dealer or
visit the Polaris web site at www.polarisindustries.com.
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SAFETY
+
General
Alert
+
Hill
Operation
Alert
+
Age 16
Alert
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If a decal
becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety decals are provided by Polaris at no
charge. The part number is printed on the decal.
The following pages repeat the information found on each decal.
General Alert
(Multi-Lingual)
Before you operate or
ride this vehicle, read
the owner’s manual.
Hill Operation Alert
• Never operate this vehicle on HILLS
steeper than 15 degrees 15°.
• To prevent flip-over on hilly terrain,
when going up or down, use throttle
and brakes gradually.
15
SAFETY
+
+
Front Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert
Rear Rack
Warning
+
Reverse Override
Alert
Safety Decals and Locations
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY 568 LBS. (258 kg)
INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
Read Owner's Manual for more detailed loading information.
Reverse Override Alert
Pushing reverse override button may cause sudden increases in power and
traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in 4X4 (AWD). See Owner's Manual.
16
SAFETY
Safety Decals and Locations
Rack Warning, Front and Rear
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
Clutch Cover Alert
NO STEP
17
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
18
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
19
FEATURES AND CONTROLS
Horn Switch
Hazard
Switch
Main Key Switch
Engine Stop Switch
Headlight
Switch
4X4 Switch
Turn Signal Switch
Mode/Reverse
Override Switch
Differential
Switch
Switches
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page 32.
To gain additional power while operating in reverse, press the override
switch before opening the throttle. This will cancel the reverse speed
limit function.
NOTE: The override switch also allows activation of 4X4 in reverse, if the 4X4
switch is on.
WARNING
Activating the override switch while the throttle is open can cause loss of
control, resulting in severe injury or death. Do not activate the override switch
while the throttle is open.
20
FEATURES AND CONTROLS
Engine
Stop Switch
Light
Switch
Switches
Main Key Switch
End all electrical power to the vehicle.
LIGHTS ON position turns the headlights on.
Start the engine. The headlights are not on in this position.
After starting the engine, release the key switch to the POSITION
LIGHTS ON position.
Do not attach a large key fob or key ring to the main switch. It may contact the
gas tank cap when turning, causing an interruption to the electrical system and
an unexpected engine shut-down during operation. This could result in serious
injury or death.
Engine Stop Switch
The engine will not start or run when
the switch is in the OFF position.
OFF
RUN
Light Switch
The lights do not operate unless the
main key switch is on and the engine
stop switch is in the RUN position.
High Beam
Low Beam
21
FEATURES AND CONTROLS
4X4 Switch
Tu r n
Indicators
Hazard Warning
Switch
Differential
Switch
Horn Switch
Turn Signal
Switch
Switches
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4 or 2X4. See
page 30.
Hazard Warning Switch
Push the hazard warning
switch to cause all turn
signal lights to flash
simultaneously . Use this
feature to alert others of
an emergency or other
situation requiring
caution.
Turn Signal Switch
Push the toggle switch
either left or right to
activate the corresponding
turn signal light. The
indicator on the pod will
also flash. Return the
toggle to the center
position and push it
inward to end the signal.
Horn Switch
Press the horn switch to sound the horn.
22
FEATURES AND CONTROLS
Switches
Differential Switch
Use the differential switch to lock and unlock the rear differential.
Locked Differential: Operate the vehicle with the switch in
the locked position in most conditions.
Unlocked Differential: When the differential is unlocked, the
inside wheel will rotate independently from the outside wheel
during turns. Operate with an unlocked differential only as
needed to protect smooth, level surfaces from tire damage.
Otherwise, move the switch to the locked position. This feature
will function only if the vehicle is in 2X4 mode.
Operating with the differential unlocked ( ) when on sloped, uneven, or loose
terrain could cause loss of control and result in serious injury or death. One rear
wheel may slip and lose traction or may lift up and grab when it touches the
ground again.
DO NOT operate with the differential unlocked ( ) when climbing or
descending hills, when sidehilling, or when operating on uneven, loose, or
slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings.
Place the differential switch in the locked position and operate in ADC 4X4 or
4X4 on these types of terrain.
23
FEATURES AND CONTROLS
Electronic Throttle Control
Throttle Lever
Press the throttle lever to increase
engine speed and vehicle movement. Release the lever to reduce
engine speed and vehicle movement.
WARNING
Failure to check or maintain proper operation of the throttle system can result
in an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate a Quadricycle with sticking or improperly operating
throttle controls. Contact your dealer for repair if throttle problems arise.
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the Quadricycle.
Electronic Throttle Control (ETC)
ETC causes the engine to
stop if the throttle cable sticks
in an open position when the
operator releases the throttle
lever.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify the ETC system or replace it with other
throttle mechanisms.
24
FEATURES AND CONTROLS
Foot Brake
Foot Brake
The all-wheel foot brake is
located on the right footrest. The
foot brake operates both front
and rear brakes. Press the brake
pedal down with your foot to
apply the all-wheel brakes.
If the rear wheels begin to skid
or slide while using the foot
brake, reduce brake pressure.
Hand Brake Lever
The hand brake operates both front
and rear brakes. Squeeze the brake
lever toward the handlebar to apply
the all-wheel brakes.
If the rear wheels begin to skid or
slide while using the brake, reduce
lever pressure.
WARNING
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause
the rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems
on this vehicle. Always use caution whenever applying the brakes.
25
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in PARK.
2. Squeeze the brake lever toward the
handlebar.
3. Push the parking brake lock forward to
engage the lock. Release the brake
lever.
4. To release the parking brake lock,
squeeze and release the brake lever.
WARNING
Operating the Quadricycle while the parking brake is engaged could result in
an accident and serious injury or death. Always release the parking brake
lock before operating.
26
FEATURES AND CONTROLS
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
1. Turn the handlebars to the full
right position.
NOTE: The handlebars may also be
2. Insert the steering lock key and
3. Remove the key.
NOTE: Place the steering lock keys in
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
locked in the full left position.
turn it clockwise.
a safe place. The lock must
be replaced if the keys are lost.
27
FEATURES AND CONTROLS
Fuel Tank
Cap
Fuel Tank Cap
Remove the fuel tank cap to
add fuel to the fuel tank. Use
either leaded or unleaded gasoline with a minimum pump
octane of 87. Do not use E-85
fuel.
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after
every 100 hours of operation or
annually. Do not attempt to
clean the fuel filter.
28
FEATURES AND CONTROLS
Gear
Selector
Latch
Automatic Transmission Gear Selector
The transmission gear selector
is located on the right side of
the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
Whenever the vehicle is left
unattended, always place the
transmission in PARK. The
transmission is locked when
it’ s in PARK.
Shifting gears with the engine speed above idle or while the vehicle is moving
can cause transmission damage. Stop the vehicle, release the throttle and move
the shift lever to the desired gear. See your dealer if you experience any shifting
problems.
Passenger Seat
Always make sure the passenger
seat is installed and securely
latched before operating with a
passenger. Test the seat latch by
attempting to pull the seat
upward.
NOTE: If the latch is not working properly, do not allow a passenger to ride the
To remove the seat, pull the latch loop at the rear of the seat. Pull the
seat upward to remove it from the vehicle.
T o reinstall the seat, make sure the rubber feet at the base of the seat are
positioned in the rear rack. Press down firmly on the seat pad until the
latch clicks
vehicle. See your Polaris dealer for service.
29
FEATURES AND CONTROLS
All Wheel Drive (4X4) System
The All Wheel Drive system is controlled by the 4X4 switch.
ADC 4X4
When the switch is on ADC
4X4, the ADC system allows
engine braking to all four
wheels when the vehicle
descends a hill or incline.
Always move the 4X4 switch to
ADC 4X4 before ascending or
descending a hill. See page 31.
4X4
When the switch is on 4X4,
the vehicle is in 4X4, and the
4X4 indicator light in the
instrument cluster will be on.
When in 4X4, the demand
drive unit will automatically
engage any time the rear wheels lose traction. When the rear wheels
regain traction, the demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4.
NOTE: The override switch allows activation of 4X4 in reverse if the 4X4
switch is on. See page 20.
2X4
When the switch is on 2X4,
the vehicle is in two-wheel
drive at all times.
30
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