Polaris Sportsman Forest 800 User Manual
PMS 419
Sportsman Forest 800
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
• 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
needs during (and after) the warranty period.
For more information about POLARIS, visit us online at www.polarisindustries.com.
®
utility vehicles
®
®
(MSD) technician. Please see your dealer for all of your service
1
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS
Industries Inc.
Copyright 2011 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2012 SPORTSMAN FOREST 800 Owner’s Manual
P/N 9923428
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Emission Control Systems . . . . . . . . . . . . . . . 69
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 118
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 124
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
5
INTRODUCTION
####
VIN
(front or rear frame)
Engine Serial Number
Key Number
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
6
SAFETY
Safety Training
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.
7
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield. POLARIS recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best
protection.
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS
ATV any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your POLARIS ATV is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
9
SAFETY
WARNING
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.
Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified instructor.
Never permit others to operate the vehicle unless
they have read and understand this manual and all
product labels, and have completed a certified
safety training course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.
Even though a child may be within the
recommended age group for operating some ATVs,
he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and
could be susceptible to accident or injury.
10
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
11
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Using Alcohol or Drugs
Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.
Never carry a passenger on this ATV.
12
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.
SAFETY
13
SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or overturn.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 53.
14
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or overturn.
• Always follow proper procedures for traveling down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling downhill. See page 55.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 54.
Never attempt to turn the ATV around on any hill
until you've mastered the turning technique (on
level ground) as described in the owner's
manual. See page 56.
15
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.
• Always maintain a steady speed when climbing
a hill.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the brakes.
• Lock the parking brake when fully stopped.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 56.
If the ATV begins rolling downhill:
• Keep body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 56.
Operating on Steep Hills
Operating on excessively steep hills could cause
an overturn.
Never operate on hills too steep for the ATV or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.
16
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.
Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control or
overturn.
Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.
SAFETY
17
SAFETY
Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 59.
Before shifting into reverse gear, always check for obstacles or people behind
the ATV. When it's safe to proceed, back slowly.
Improper Tire Maintenance
Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.
Always use the size and type of tires
specified for your ATV.
Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.
18
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 58.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.
Operating Through Deep Water
Operating the ATV through deep or fastflowing water could cause the tires to float,
causing loss of control or overturn.
Avoid operating the ATV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page
57):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.
19
SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.
• Never exceed the stated load capacity for this ATV.
• Cargo should be properly distributed and securely attached.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving
force of the ATV, you and your cargo, together with any other vehicles in your
party. Variances in snow depth and/or water currents may result in uneven ice
thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. ATV operators assume all risk associated with ice conditions on frozen bodies of water.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.
20
SAFETY
Safety Warnings
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
21
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
22
Safety Labels and Locations
Tire Pressure/Load
Warning
General Warning
Discretionary
Warning
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 515 lbs. (234 kg)
SAFETY
Discretionary Warning
WARNING
• Never operate this ATV on HILLS
steeper than 25 degrees 25. To prevent overturn on hilly terrain, use throttle
and brakes gradually, and shift weight
uphill.
• REVERSE operation can be dangerous
even at low speeds. Steering becomes
difficult. To prevent loss of control, avoid
sudden braking or sharp turns.
23
SAFETY
“No Passenger”
Warning
Age 16
Warning
Rack
Warning
Rack
Warning
Clutch Cover
Warning
Hitch
Capacity
Safety Labels and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this ATV if you are under age 16.
24
SAFETY
Safety Labels and Locations
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
NO STEP
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.
• Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)
Reverse Override Warning/4X4 Caution
WARNING
Improper use of the override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
25
FEATURES AND CONTROLS
Mode/Reverse
Override
Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
AWD
Switch
OUT
IN
Winch Switch
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system.To gain
additional wheel speed while backing, release the throttle and depress
the override button.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
The override switch also allows activation of AWD in reverse, if the
AWD switch is on. This switch is also used to toggle through the modes
of the rider information center. See page 35.
AWD Switch
Use the AWD switch to engage 4X4 or 2X4. See page 34.
Winch Switch
See page 63 for winch information.
26
FEATURES AND CONTROLS
OFF OFFRUN
Switches
Engine Stop Switch
Move the stop switch either
left or right to the OFF position
to stop the engine quickly. The
engine will not start or run
when the switch is off.
Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 49 for starting procedures.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position to operate the
headlights.
27
FEATURES AND CONTROLS
WARNING
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.
Engine speed and vehicle movement are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.
This ATV is equipped with
POLARIS Electronic Throttle Control (ETC), which is designed to
reduce the risk of a frozen or stuck
throttle. If the throttle cable should
stick in an open position when the operator releases the throttle lever,
the engine will stop, and power to the rear wheels will cease.
28
FEATURES AND CONTROLS
WARNING
Brake Lever
Operating the ATV with a spongy brake lever can result in loss of braking, which
could cause an accident. Never operate the ATV with a spongy-feeling brake
lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
hydraulically activated disc type
brakes that are activated by only
one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
29
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