Page 1 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.
Page 2 COPYRIGHT INFO 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.
Page 3 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.
Page 5 GENERAL INFORMATION MAINTENANCE ENGINE FUEL SYSTEM - GENERAL BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 8: Model Information
WORLD MFG. ID INDIVIDUAL SERIAL NO. LIN- SIZ- TIO- FIE- * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 9: Engine Number Designation
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).
Page 10: 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. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 11: Sportsman 800 Efi 4X4 Specifications
Liquid - 3.6 qt/ 3.4 ltr. HOT on Instrument Overheat Warning Cluster Pressurized Wet Sump Lubrication Oil Requirements / Polaris 2W-50 2 qt. / 1.9 Capacity liters Exhaust System Single Pipe / Silencer Fuel System Fuel Pump 25L per hour at 39 PSI...
Page 12 25 x 8 - 12 Rear Tire Size 25 x 11 - 12 5 psi (34.5 Kpa) Tire Pressure F/R Dual Hydraulic Disc Brake - Front and Rear 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 13: Sportsman 800 Efi Big Boss 6X6 Specifications
Height 48 in. / 119.4 cm capacity not to exceed 800 lbs. Seat Height 34 in. / 86.4 cm (362.87kg) Wheel Base 79.5 in. / 201.93 cm 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 14: 2012-2014 Sportsman 800 Efi Big Boss 6X6
Progressive Rate Pressurized Wet Sump Lubrication Rear Suspension / Shock Independent - Oil Requirements / Coil - over shock Polaris 2W-50 2 qt. / 1.9 Capacity liters Rear Travel 6.12 in. / 15.54 cm Exhaust System Single Pipe / Silencer Ground Clearance 10.50 in.
Page 15: Publications / Paint Codes / Keys / Tools
9924604 (AA) 2014 A14CF76AA, FA Big Boss 6x6 9924416 (FA) 9924752 (FA) Paint Codes COLOR DITZLER POLARIS PAINTED PART NUMBER DESCRIPTION NUMBER Sportsman 800 Frame Black 9440 P-067 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 16: 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/.
Page 17: Misc. Numbers/Charts
= cylinder volume π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 1.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 18: Sae Tap / Drill Sizes
5/16–18 2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 1.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 19: Standard Bolt Torque Specification
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) 1.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 20: Decimal Equivalents
0.5156″ 17/32 0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 0.5625″ 9/16 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 1.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 21 ......2.7 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS LUBRICATION / FLUIDS ................. 2.8 .
Page 23: Maintenance
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/.
Page 24: Periodic Maintenance Chart
▶ = 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. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 25 ▶ = 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. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 26 ▶ = 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. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 27: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products PART NO. DESCRIPTION PART NO. DESCRIPTION Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. Fogging Oil (12 oz. Aerosol) Loctite™ Threadlock 242 2870791 2871950 (6 ml.) (12 count)
Page 28: Lubrication / Fluids
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.
Page 29: Lubrication / Grease Points (6X6)
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.
Page 31: Oil/Filter Change
Filter Wrench PU-50105, turn filter counterclockwise dipstick. to remove. 16. Dispose of used filter and oil properly. 9. Using a clean dry cloth, clean filter sealing surface on crankcase. 2.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 32: Front Gearcase Lubrication (4X4)
Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page. 5. Install / torque fill plug and check for leaks. 2.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 33: Front Gearcase Lubrication (6X6)
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. 2.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 34: Adc Differential Hydraulic Circuit Fluid Change (6X6)
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. 2.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 35: Transmission Lubrication (4X4)
Transmission Drain Plug: 14 ft-lbs (19 Nm) 3. Remove fill plug. Transmission Check/Fill Plug: 4. Add the correct amount of Polaris AGL Gearcase 14 ft-lbs (19 Nm) Lubricant. To Check the Fluid Level: Remove check / fill plug (A) from the left side of transmission and visually inspect the oil level.
Page 36: Transmission Lubrication (6X6)
• Check vent hose to be sure it is routed properly 3. Remove fill plug (A). and unobstructed. 4. Add the correct amount of Polaris AGL Gearcase • Follow instructions to check / change transmission Lubricant. lubricant. 5. Check for leaks.
Page 37: Middle Gearcase Lubrication (6X6)
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. 2.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 38: Rear Gearcase Lubrication (6X6)
Remove the check / fill plug. The fluid level should be at the bottom of the check / fill plug case threads. See next page. 5. Install / torque fill plug and check for leaks. 2.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 39: Vehicle Inspection
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. 2.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 40: Throttle Cable / Throttle Release System (Trs Switch) Adjustment
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 2.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 41: Compression Test
Cylinder Compression Standard: 150-200 PSI Cylinder Leakdown Service Limit 15% (Inspect for cause if test exceeds 15%) 2.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 42: Spark Plug
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 © Copyright 2013 Polaris Sales Inc.
Page 43: Battery Maintenance
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. 2.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 44: Cooling System
• 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.
Page 45: Reservoir Level Inspection
Use of a non-standard pressure cap will not allow the recovery system to function properly. 2. Fill reservoir (A) to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a To Access the Radiator Pressure Cap and add fluid: mixture of antifreeze and distilled water as required for freeze protection in your area.
Page 46: Radiator/Grill Screen
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 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 47: Air Filter/Pre-Filter Service
See the pre filter with hot, soapy water. Illustration above. 6. Rinse and dry thoroughly. 11. Install air box cover and secure with the (6) clips. 2.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 48: Air Box Sediment 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. 2.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 49: Pvt Inspection / Drying Procedure
Operate ATV in lowest available range for a short period of time until PVT system is dry. 2.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 50: Camber/Caster
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.
Page 52: Wheel Alignment
• After alignment is complete, torque jam nuts to specification. Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 2.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 53: Exhaust Pipe
2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times. 2.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 54: Brake System Inspection
• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. • Use Polaris DOT 4 Brake Fluid • Use Polaris DOT 4 Brake Fluid • Check brake for excessive travel or spongy feel.
Page 55: Brake Pads
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. 2.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 56: Auxiliary Brake Adjustment
Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9. 2.36 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 57: Cv Shaft Boot Inspection
Brake control and switch must be positioned to allow boot. Refer to Chapter 7 for CV boot replacement, or brake lever to travel throughout entire range without have your Polaris dealer replace the boot. contacting switch body. Wheel Inspection Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight.
Page 58: Frame, Nuts, Bolts, Fasteners
(41 Nm + 1/4 Turn) Front Hub Retaining Nut 60 ft-lbs (81 Nm) Rear Hub Retaining Nut 80 ft-lbs (108 Nm) 4. Remove the wheel nuts and remove the wheel. 2.38 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 59: Tire Pressure
Worn tires can cause an accident. Always replace tires when the tread depth measures 1/ 8inch (.3 cm) or less. 2.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 71: Torque Specifications
* 96 ± 3 (10.85 ± 0.35) 6 mm Water Pump Impeller Nut 108 ± 3 (12 ± 0.35) 8 mm NOTE: * See exploded views for notes or torque sequences. 3.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 72: 800 Efi Engine Service Specifications
Valve Spring Overall Length - Free Length 1.735" (46.069 mm) Valve Spring Valve Spring Overall Length - Installed Intake - 1.4638" (37.18 mm) Height Exhaust - 1.4736" (37.43 mm) 3.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 73 (0.012 ± 0.006 mm) Piston Pin Piston Pin - Degree of Fit Piston pin must be a push fit (by hand) at 68° F (20° C) 3.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 74 Connecting Rod Big End (0.030 ± 0.015 mm) Side Clearance 0.0015"± 0.00006" Connecting Rod Big End (0.0038 ± 0.0015mm) Radial Clearance 0.00236" (0.060mm) Crankshaft Crankshaft Runout Limit 3.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 75 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 3.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 76: General Engine Service
Following Components Require Engine Removal for deposits which may restrict coolant flow and reduce heat service: dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for • Counterbalance Shaft or Bearings use in all cooling systems and comes pre-mixed, ready to use.
Page 77: Cooling System Pressure Test
5. The filler cap relief pressure is 13 psi. Replace cap if fan comes on. Make sure the fan comes on before it does not meet this specification. the hot light. 3.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 78: Engine Removal (Typical)
17. Disconnect coolant temperature sensor wire located on the cylinder. 18. Remove engine to chassis ground cable. 10. Disconnect spark plug high tension leads. 3.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 79: Engine Installation Notes
12. Again, remove radiator cap and slowly add coolant to engine is too heavy to be lifted manually. the bottom of fill neck if needed. 21. For engine installation, reverse procedures. 3.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 80: Cylinder Hone Selection And Honing Procedure
Engine Break-In Period Polaris recommends using a rigid hone or arbor honing The break-in period for a Polaris ATV engine is machine. Cylinders may be wet or dry honed depending defined as the first ten hours of operation, or the time upon the hone manufacturer's recommendations.
Page 81: Honing To Deglaze
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. 3.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 82: Oil Flow Chart
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 © Copyright 2013 Polaris Sales Inc.
Page 83: Engine Lubrication Specifications
Oil Type - Polaris PS4 2W/50 Synthetic 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.
Page 84: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View 3.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 85: Rocker Arms
CAUTION Do not attempt to true this surface by grinding. 3. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs. 3.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 86: Cylinder Head Removal
.004" (.1016 mm) max 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 © Copyright 2013 Polaris Sales Inc.
Page 87: Valve Seal/Spring Service (On Engine)
3. Remove spring retainer and spring. 4. The valve seals are now serviceable. 3.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 88 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. 3.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 89: Valve Inspection
(B). NOTE: The valves can be re- faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged. 3.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 90: Combustion Chamber
Valve Seat Reconditioning 0.23672" + 0.000295" (6.0617 + 0.0075 mm) NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. 7. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide The cylinder head valve guides cannot be replaced.
Page 91 6. Insert valve into guide and tap valve lightly into place a few times. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 3.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 92 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. 3.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 93: Cylinder Head Reassembly
Install new valve seals on valve guides. 5. Dip valve spring and retainer in clean engine oil and install. 3.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 94: Valve Sealing Test
3. Rock cylinder forward and backward while lifting it from crankcase, supporting pistons connecting rods. Support pistons with Piston Support Block (PN 2870390). 3.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 95: Valve Lifter Removal/Inspection
4. Check the lifters for wear or scores. 5. Check the bottom end of lifter to make sure that it has a slight convex. 3.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 96: Piston Removal
*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. 3.36 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 97: Cylinder Inspection
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. Cylinder Warp: .004" (0.1 mm) Max. 3.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 98: Piston-To-Cylinder Clearance
Step 5. 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) 3.38 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 99: Piston/Rod Inspection
REMINDER: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. 3.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 100: Starter Drive/Bendix Removal Inspection
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. 3.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 101: Flywheel / Stator Removal / Inspection
(A). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils 5. Remove the bendix (D) if necessary. may be damaged. 3.41 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 102: Engine Crankcase Disassembly / Inspection
2. Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller. 3. Remove flywheel nut and washer. 3.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 103 10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly. 3.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 104 12. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1). 14. Inspect the gear teeth and the three tabs on the gears for wear. 3.44 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 105 * Perform this procedure with all three tapered pins. * Do not push the pins too far through or the springs will pop out. NOTE: Do not remove the tapered pins at this time. 3.45 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 106 (PN 2871043) to remove the balance shaft gear. For ease of installing the Cam Gear Alignment Tool (PU-45497-2) (R), use a twisting motion when pushing down on the tool. 3.46 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 107 24. Install the two puller bolts (R). Tighten the puller bolts bolts with a hex wrench. Pull out the pump. up so that the bolts are at equal length. 3.47 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 108 NOTE: Be sure to place the tapered end of the valve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur. 3.48 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 109 Protective gloves, clothing and eyewear are required. result. Install retaining ring. 32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly. 3.49 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 110 Loctite. This will prevent any possible damage to the bolts or to the crankcase casting. 39. Remove and clean oil pick up (V) and oil baffle weldment (W). 3.50 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 111: Camshaft Inspection
Cam Lobe Height (Intake & Exhaust): Std.: 1.3334" (33.8674 mm) NOTE: Plain bearing clearances may be checked using a commercially available plasti-gauge material. 3.51 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 112 NOTE: Replace camshaft if damaged or if any part is worn past the service limit. Replace engine block if camshaft journal bores are damaged or worn excessively. 3.52 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 113: Engine Reassembly
2. Install oil baffle weldment (B). Torque bolts to specification. Oil Baffle Weldment & Oil Pick Up Bolt: 60 ± 6 in-lbs (6.8 ± 0.68 Nm) 3.53 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 114 Torque bolts to specification following torque pattern at beginning of this chapter. Crankcase Bolt: 22 + 2 ft-lbs (30 + 3 Nm) Torque in sequence 3.54 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 115 NOTE: To help align the pistons, slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder. 3.55 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 116 12 O'clock position. piston and connecting rods. IMPORTANT: While installing in piston pins, cover all engine passages. The clip could fall into the engine during installation. 3.56 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 117 Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite® 3.57 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 118 NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with This Side Out." This indicates the side of the gear that faces outward or away from the case. 3.58 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 119 Wrench (PU-45498) to rotate the cam to the proper position. Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. 3.59 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 120 The water pump seal cannot be removed or installed with the gear/ stator housing attached to the engine. Shaft damage will occur. 3.60 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 122 With the tools installed, carefully place the gear/stator housing cover over the protection tools. 35. Install the gear/stator housing gasket onto he crankcase. 3.62 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 123 Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 37. Install shaft seal with ceramic surface facing inward. 3.63 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 124 NOTE: There are thrust washers on both sides Stator Assembly Bolt: of starter drive. 96 in-lbs (10.85 Nm) 41. Install stator assembly (S) and bolts. Torque bolts to specification. 3.64 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 125 System Priming Adapter (PU-45778) into the oil plug 65 ± 7 ft-lbs (88 ± 9.50 Nm) hole. Push 3-5 oz. (approx.) of Polaris 2W-50 into the adapter or until resistance is felt. Remove the 44. Install stator housing with new o-rings. Torque the adapter.
Page 126: Flywheel / Stator Installation
3. Install the starter bendix if removed. 4. Install woodruff key. Install the flywheel. Install the flywheel washer and nut. Torque the flywheel nut to specification. Flywheel Nut: 65 ft-lbs (88 Nm) 3.66 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 127: Cylinder Head Installation
Follow bolt torque sequence on found at the beginning of this chapter. Stator Housing Bolt: 96 3 in-lbs (1.85 Nm) *Torque in Sequence 3.67 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 128 Torque bolts specification. 4. Lubricate push rods (D) and install into lifters. Rocker Arm Bolt: 22 + 2 ft-lbs (30 ± 3 Nm) 3.68 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 129 84 ± 8 in-lbs (9.5 ± 0.9 Nm) Torque in Sequence 11. Install thermostat (J), new O-ring, and thermostat housing. Torque to specification. Thermostat Housing Bolt: 84 ± 8 in-lbs (9.5± 0.9 Nm) 3.69 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 130 ENGINE 12. Install temperature sender (K) and torque to specification. Temperature Sender: 25 ± 3 ft-lbs (34 ± 4 Nm) 3.70 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 131: 800 Efi Exhaust System
Washer, Rubber Washer, Clean Out Washer Washer Screw Bolt Manifold, Black Screw Grommet Seal, Exhaust Shield, Outer Dampener, Vibration Sprint, Exhaust Isolator Bushing Pipe, Exhaust Gasket 3.71 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 132: Troubleshooting
• Restricted breather • Air filter dirty or contaminated Engine Runs But Will Not Idle • Restricted carburetor pilot system • Low compression • Crankcase breather restricted 3.72 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 133: Cooling System
Ignition coil faulty, Ignition or kill switch • Faulty pump shaft oil seal (oil leak) circuit faulty, Ignition poor connections in ignition system • Timing incorrect, Sheared flywheel key • Valve sticking 3.73 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 137: General Information
Special Tools PART NUMBER TOOL DESCRIPTION Polaris EFI Diagnostic Software PU-47063-A (Digital Wrench) Polaris EFI Diagnostic Software (Digital Wrench®) - Fuel Pressure PU-43506-A PU-47063-A Test Kit This dealer-only software installs on laptop computers Fuel Pressure PU-48838 equipped with a CD drive and serial port connection, and...
Page 138: Service Notes
Bosch Automotive Service Solutions (1-800-345-2233) Interface Cable PU-47469 and PC Interface Cable PU- This kit contains the necessary cables and hardware to 47470. For use on all 15-pin connector-based Polaris EFI communicate between the vehicle ECU and the Digital systems.
Page 140: Efi System Component Locations
6. Fuel Pump / Regulator / Gauge Sender Assembly (located in tank) 7. Throttle Position Sensor (TPS). Located on the RH side of the throttle body. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 141: Diagnostic Connector And Fuses
9. Engine Coolant Temperature Sensor (ECT). Located my the thermostat on the cylinder head, on the LH side of the engine. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 143: Fuel Lines - Quick Connect
4. Snap the fuel line back over the nipple and slide the locking mechanism back into place. Verify the connector tabs snap back into place. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 144: Electronic Fuel Injection
During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air/fuel ratio is automatically calculated by the ECU. 4.10 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 145: Initial Priming / Starting Procedure
If the engine fails to start, a problem may still exist, and should be diagnosed. IMPORTANT: Accurate testing components recommended utilizing Polaris Diagnostic Software (dealer only). 4.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 146: Electronic Control Unit (Ecu)
RPM limit (6500) is exceeded, the ECU suppresses the injection signals, cutting off the fuel flow. This process repeats it self in rapid succession, limiting operation to the preset maximum. 4.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 147: Ecu Service
TPS to the throttle body is altered, the TPS must be re-initialized. For the purpose of troubleshooting, a known-good ECU from another Polaris ATV EFI of the same model may be used without system or engine component damage. 4.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 ©...
Page 148: Fuel Pump
1. Remove the fuel rail end cap (damper). 2. Connect the fuel rail end cap (damper) onto adapter PU-47476 and install on the fuel rail. 3. Attach Polaris pressure tester PU-43506. Route the tester clear hose into a portable gasoline container or the equipment fuel tank.
Page 149: Fuel Pump / Tank Assembly Replacement
NOTE: A small amount of fuel may come out of the fuel line or tank. Plug the fuel line and tank inlet or use a shop towel during removal. 4.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 150 NOTE: Properly route the gas tank vent line, use tape to secure the vent line in place. 14. Reconnect the negative battery cable. Test the sender for proper operation. 4.16 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 151: Fuel Sending Unit
Empty: approx 5 Ω 3. Move the seal out of the sealing channel and pull up on the front of the access cover. Remove the access cover. 4.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 152: Fuel Pump Replacement
11. Remove new fuel pump assembly, gasket and PFA nut from packaging. Use care not to bend float arm during un-packaging. Do not lift or carry fuel pump assembly by the float arm. 4.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 153 PFA nut onto fuel tank and hand tighten. Use care when starting PFA nut, ensuring threads are properly aligned. Verify orientation marks are still aligned between fuel pump and fuel tank. 4.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 154 23. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 155: Fuel Tank Vent Routing
Fuel Pressure Regulator Replacement The regulator is a sealed, non-serviceable assembly. If it is faulty, the pump assembly must be replaced. Refer to the Fuel Pump Replacement procedure. 4.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 156: Fuel Injectors
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 157: Fuel Injector Replacement
Lubricate o-rings lightly with oil to aid installation. Torque the fuel rail mounting screw to specification. Fuel Rail Mount Screws: 18 ft-lbs (24 Nm) 4.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 158: Crankshaft Position Sensor (Cps)
This sensor must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will quit running. 4.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 159: Crankshaft Position Sensor (Cps) Replacement
3. Torque the retaining bolt to specification. CPS Retaining Bolt: 25 in-lbs (2.8 Nm) 4.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 160: Temperature / Barometric Air Pressure Sensor (T-Bap)
BAP) is a non-serviceable item. If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate, therefore the T-BAP sensor should only be tested using the Polaris Diagnostic Software (dealer only). Refer to Diagnostic Software...
Page 161: Throttle Position Sensor (Tps)
.730 Vdc, the learn function is set to default to the last successfully learned point and the “Check Engine” or “MIL” indicator will illuminate. Performing the “TPS Adjustment” procedure will remedy this problem. VERIFY CORRECT REFERENCE VOLTAGE 4.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 162: Throttle Position Sensor Replacement
“Y” and “BK” ports and the meter set to Vdc, slowly open and close the throttle while reading the display. The voltage should increase smoothly with no “jumps” or decreases when the throttle is applied. 4.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 163: Throttle Position Sensor Adjustment
If changed, repeat steps 3, 4, 5 and 6 or inspect throttle body for possible wear or damage. 7. Reconnect the TPS harness lead. 8. Reinstall throttle body. Adjust cable freeplay if required. 4.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 164: Engine Temperature Sensor
‘HOT’ should indicate on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 10 for ETS testing. Polaris dealers can also test the sensor by using the Polaris Digital Wrench® Software (dealer only). Refer to the Digital Wrench®...
Page 165: Ignition Coil
4. Install the new ignition coil and/or high tension lead (s). Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 4.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 166: Ignition Coil Tests
Primary 0.4 Ω Between 2 & 3 Long: 2.46 kΩ ±6% Between High Tension Secondary Short: 2.07 kΩ Lead End Caps ±6% Primary Test Secondary Test 4.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 167: Digital Wrench® Operation
NOTE: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 168: Digital Wrench® Communication Errors
‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 4.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 169: Digital Wrench® Serial Number Location
1. Open the Digital Wrench® software. Locate the version ID shown on the lower right side of the Digital Wrench® start-up screen. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 3. If a newer update is available, it should be downloaded before using Digital Wrench®...
Page 170: Digital Wrench® Updates
(see “Digital Wrench® Updates are released for Digital Wrench® via the Version and Update ID”), download the file. Internet at: http://polaris. diagsys. com. The Digital Wrench® website can also be accessed through the dealer website at: www.polarisdealers.com.
Page 171 8. When the update is complete, the version shown on the right side of the Digital Wrench® start-up screen should match the update you just downloaded. NOTE: Versions and updates are subject to change. 4.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 173: Ecu Replacement
ECU, an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash • Proceed to http://polaris. diagsys. com for specific Authorization site. The Request Code is automatically information and FAQs on how to troubleshoot generated by Digital Wrench®...
Page 174 4. Select the model year, product line and vehicle click the “Continue” icon to proceed to the Integrity description by selecting the “Change Vehicle Type” Check and obtain a Request Code. icon. 4.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 175 ‘Continue’ button and follow instructions provided on the screen to complete the reprogramming procedure. 10. Enter or paste (CTRL+V) the Request Code into the box. 4.41 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 176 PC during the process. 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 177: Troubleshooting
P1233 Cooling Fan: Open Load P1480 Cooling Fan: Short Circuit to Ground P1481 Cooling Fan: Short Circuit to Battery P1482 End of Diagnostic Check – – 4.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 180: Efi Circuit - Temperature - Barometric Air Pressure Sensor
FUEL SYSTEM - GENERAL EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor EFI CIRCUIT - Engine Temperature 4.46 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 182: Efi Troubleshooting
Symptom: Idle Too Low (if less than 900 RPM when engine is warm) • Plugged air filter • Leaking injector (rich condition) • Belt dragging • Throttle stop screw tampering 4.48 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 184: General Information
Shock Spring Compression Tool 2870623 2871572 Strut Rod Wrench LH Strut Spring Compressor 2871573 RH Strut Spring Compressor 2871574 2876389 Multi-Function Pliers Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 185: Decal Replacement
Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 2. Apply the decal. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 186: Body
With a firm motion, pull the panel outward to disengage the side panel from the grommet. Pull the panel downward and rearward to remove it from the ATV. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 187: Front Storage Box Lid / Front Rack And Access Panel Removal / Installation
/ front rack. 5. Remove the (2) T-27 screws that attach the front storage box lid / front rack to the front bumper. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 188: Foot Well Removal / Installation
7. Remove the front bumper by gently the pulling the lower portion of the bumper away from the vehicle frame and sliding it down. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 189: Mud Guard Removal / Installation
5. Reverse this procedure to reinstall the mud guards. 6. Torque the T27 fasteners to specification. Font Bumper Retaining Fasteners: 5 ft-lbs (7 Nm) Mud Guard Retaining Fasteners: 5 ft-lbs (7 Nm) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 190: Front Fender Removal/Installation
5. Remove the seat and side panels, refer to the “SIDE PANEL REMOVAL” section. 6. Remove the plastic inserts (D) that secure the front of the foot wells to the front fender. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 191: Front Rack / Storage Box Lid Assembly (4X4 And 6X6)
BODY / STEERING / SUSPENSION Front Rack / Storage Box Lid Assembly (4x4 and 6x6) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 197: Headlight Pod Exploded View
• Install one rear Phillips screw • Remove two screws securing bottom half of pod • To adjust headlight, refer to procedure outlined in Chapter 2 5.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 198: Winch And Front Bumper Mounting (4X4 And 6X6)
BODY / STEERING / SUSPENSION Winch and Front Bumper Mounting (4x4 and 6x6) 5.16 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 199: Rear Fender Panel Removal / Installation (6X6)
1. Raise the cargo box and remove the seat. 4. Reinstall the plastic inserts. 2. Remove the plastic inserts (circled) that secure the fender panel to each rear footwell. 5.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 202: Steering
5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification. NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed. 5.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 203: Steering / A-Arm Exploded View
The steering post arm bolt (B) points up; the rod end bolts (A) point down. Verify inner rod ends are placed between the steering post arms. 5.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 204: A-Arm Replacement
The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation. 5.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 205: Ball Joint Replacement
14. Remove extension cap and attach puller guide using short bolts provided in the kit. 15. Insert new ball joint (K) into driver (L). 5.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 206: Steering Post Removal
20. Install A-arm on ball joint and torque castle nut to specification. Castle Nut: 30 ft-lbs (41 Nm) 21. Reinstall cotter pin with open ends toward rear of machine. 5.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 207: Steering Post Assembly
(A) in opposite directions. 4. Check the steering, the handle bars must move freely and easily from full left to full right without binding. 5.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 208: Suspension
Strut Rod Nut: 5. Remove two pinch bolts from strut casting. 15 ft-lbs (21 Nm) 6. Remove strut cartridge. 7. Install cartridge until bottomed in strut casting. 5.26 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 210: Rear Suspension Exploded View (4X4)
BODY / STEERING / SUSPENSION Rear Suspension Exploded View (4X4) 5.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 Service Manual © Copyright Polaris Industries Inc.
Page 212: Rear / Middle Suspension Exploded View (6X6)
BODY / STEERING / SUSPENSION Rear / Middle Suspension Exploded View (6x6) Always torque from the nut side and NOT the bolt head. 5.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 Service Manual © Copyright Polaris Industries Inc.
Page 215 6. Reverse the removal steps to reinstall the cargo box. Be careful not to over tighten the pivot bolts, as binding may result. See “Standard Torque Specifications”, page 7. Reconnect the tail light wire harnesses. 5.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 219: Pvt System Overview
PVT Inner Cover Bolts 48 in-lbs (5.4 Nm) PVT Outer Cover Bolts Drive Clutch Spider 200 ft-lbs (271 Nm) 90 in-lbs (10 Nm) Drive Clutch Cover Plate 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 220: General Operation
The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage.
Page 221: Driven Clutch Operation
Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 222: Maintenance / Inspection
PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 223: Overheating / Diagnosis
PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to prevent belt Clutch malfunction.
Page 224: Pvt System Service
Drive Clutch Holder (PN 9314177) 12. Remove cover along with foam seal on back of cover or shaft. 8. Remove the driven clutch retaining bolt and driven clutch. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 225: Assembly
14. Replace PVT outer clutch cover rubber gasket. 15. Reinstall PVT outer clutch cover and secure with screws. Torque to specification. 6. Torque rear inner cover bolts (B) to specification. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 226 Inner Cover Bolt (Rear): 12 ft-lbs (16.6 Nm) Outer Cover Bolt: 48 in-lbs (5.4 Nm) Driven Clutch Retaining Bolt: 17 ft-lbs (23.5 Nm) Drive Clutch Retaining Bolt: 47 ft-lbs (64 Nm) 6.10 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 227: Drive Belt
3. The belt then should be able to be pushed down into and between the sheaves. Be sure to position belt so part number is easily read. 6.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 228: Belt Inspection
10 hour break-in period as recommended (see Chapter 3 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break- in period. 6.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 230: Setting Center-To-Center Distance
.020” gap between the belt and stationary sheave and a larger gap between the belt and moveable sheave. 6.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 231: Drive Clutch Service (4X4 - Non Ebs)
1. Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly. 6.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 232 5. Remove and inspect the clutch spring. See “Drive Clutch Spring Specifications” for spring inspection. Color Red / Blue Free Length 2.56” (65.024 mm) Drive Clutch Spring Inspection 6.16 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 233: Shift Weight Inspection
NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 6.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 234 Roller Pin Tool (PN 2870910) to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation. 6.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 235: Button To Tower Clearance Inspection
2. Verify there is no binding or rough spots. If problems noted either direction, continue with disassembly. Button to Tower Clearance: 000-.001” 2. Inspect sheave surfaces. Replace the entire clutch if worn, damaged or cracked. 6.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 236: Clutch Inspection
4. Lift bearing (3) and thrust washer (4) off shaft. Replace as an assembly if worn, damaged, or if PTFE Washer Thickness problems were noted. Standard: .030” (.76mm) Service Limit: .025” (.64mm) 6.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 237: Moveable Sheave Bushing Inspection
“X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier, in moveable sheave. 6.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 238 6. Reinstall clutch spring. 7. Reinstall cover, aligning “X” mark with other marks. 8. Torque cover bolts evenly to specification. Cover Screw: 90 in-lbs (10.4 Nm) 6.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 239: Ebs Drive Clutch Service (6X6)
4. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 6.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 240 Drive Clutch Spring Inspection Free Length 2.8” (71.12 mm) Drive Clutch Spring Specifications 2012 Sportsman Big Boss 6x6 800 EFI Color Red / Blue Free Length 2.56” (65.024 mm) 6.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 241: Shift Weight Inspection
NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 6.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 242 Roller Pin Tool (PN 2870910) to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation. 6.26 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 243: Button To Tower Clearance Inspection
Service Limit: .025, (.64mm) 2. Lift one-way clutch (3) and thrust washer (4) off shaft. Replace as an assembly if worn, damaged, or if problems were noted. 6.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 244: Moveable Sheave Bushing Inspection
4. Visually inspect PTFE thrust washer for damage. Measure the thickness and compare to specification. Replace if worn or damaged PTFE Washer Thickness Standard: .030” (.76mm) Service Limit: .025” (.64mm) 6.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 245: One-Way Clutch Inspection (Ebs Drive Clutch)
“X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier on the moveable sheave. 6.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 246 6. Install limiter spacer on top of spider. 7. Reinstall shift weights using new lock nuts on the bolts. Shift Weight Lock Nuts: 20 in-lbs (2.3 Nm) Cover Screw: 100 in-lbs (11.25 Nm) 6.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 247: Drive Clutch Bushing Service (Non Ebs And Ebs)
Main Puller Adapter 5020632 puller threads. Adapter Reducer 5010279 Piston Pin Puller (PN 2870386) Number Two Puller 5020633 Adapter 3. Remove nut from puller rod and set aside. 6.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 248 29. Remove nut from puller rod and set aside. 30. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 6.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 249 35. Turn clutch cover counterclockwise on puller rod until bushing is seated. 36. Remove nut from puller rod. Take installation tool and clutch cover off rod. 6.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 250: Driven Clutch Service (Non Ebs)
Use caution when removing, the snap ring pressure is loaded by the compression spring. 1. Remove driven clutch from the transmission input shaft. 6.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 251 Remove snap ring and slowly release the (D). assembly. 5. Separate the two clutch sheaves. NOTE: Spring is compression only and has no torsional wind. 6.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 252 13. Lube splines with a light film of grease. Do not lubricate the bearings! 8. Check the rollers in the stationary sheave for wear. If rollers are worn, a new driven clutch assembly may be needed. 6.36 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 253: Clutch Assembly
2. Align the “X” marks on each of the sheaves during assembly. reassembly. 6. Compress the outer retainer and install the snap ring. 3. Install spring into inner retainer. 6.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 255: Clutch Disassembly
X’s on the components for reference. This will aid in reassembly and helps to maintain clutch balance after reassembly. 6.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 256 (E). Inspect the spider dampener (E) for wear and replace if needed. 7. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the rollers for wear; replace if worn. 6.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 258: Clutch Assembly
2. Install the shaft and bearing assembly into the outer sheave. IMPORTANT: Press only on the outer race of the bearing during installation to prevent from damaging the bearing. 6.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 259 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 262: Driven Clutch Bushing Service
P-90 Driven Clutch 5020631 Cover Bushing Removal 5. Install bushing tool (Item 2). Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 6.46 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 263 18. Remove nut (C) from puller rod and set aside. 11. Install puller adapter (Item 10) onto puller. 19. Remove installation tool and clutch sheave from puller. 12. Install adapter (Item 9) onto puller. 6.47 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 264: Troubleshooting
Belt burnt, thin -Vehicle operated with park brake on. Inspect -Dragging brake spots brake system. -Fast, effective use of throttle for efficient -Slow, easy clutch engagement engagement. 6.48 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 265 -Replace belt. Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.49 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 269: Specifications
Roller Pin Removal Tool CV Boot Clamp Pliers 8700226 or PU-48951 ADC Gearcase Piston PA-48542 Installation Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ Gearcase Fluid / Capacity GEARCASE DESCRIPTION Demand Drive Hub Fluid Centralized Hilliard (non ADC) 8.97 oz. (265 ml)
Page 270 Demand Drive Pump Reservoir Add As Required AGL Synthetic or ADF Middle Gearcase 13.5 oz. (400 ml) AGL Synthetic or ADF Rear Gearcase 5.0 oz. (150 ml) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 271: Front Hub
The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 272: Front Gearcase Removal And Installation (Adc And Non Adc)
5. Pull the hub and strut assembly out and pull the drive-shaft out of the gearcase. 6. Remove the roller pin from the front prop shaft. Use the Roller Pin Removal Tool (PN 2872608). 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 273: Gearcase Installation
30 ft-lbs (41 Nm) 3. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 274: Front Gearcase - Centralized Hilliard Non Adc (4X4)
FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD NON ADC (4X4) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 275 (non serviceable, see parts book) Bearing Spring Retainer (non serviceable, see parts book) Torsion Spring Thrust Button Asm. Fill Plug Retaining Ring TORQUE 8-30 ft-lbs (11-40 Nm) Vent Tube 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 277: Disassembly / Inspection Non Adc
2. Remove bolts retaining the outer cover plate assembly. 3. Remove the outer cover plate assembly. 5. Remove and inspect the armature plate. Refer to “AWD Diagnosis” for detailed inspection process. 7.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 278 10. Inspect the ring gear (C) for inconsistent wear patterns or damage. The surfaces should be free of nicks or burrs. 7.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 279 ASSEMBLY” procedure later in this chapter for details on backlash setting. 14. Remove the bolts retaining the input shaft cover and pinion gear assembly. 7.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 280 (C) for chipped, broken, or missing teeth. beginning reassembly. Inspect the input shaft bearing (D) for signs of wear. Replace the input shaft cover O-ring prior to reassembly. 7.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 281: Reassembly / Inspection Non Adc
4. Install input shaft, bearing, snap ring, and input cover with new o-ring. Torque bolts to specification. Input Cover Bolt: 9 ft-lbs (12 Nm) 7.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 283 15. Lay the gearcase on the side with the output cover facing up. NOTE: Verify the square O-ring (arrow) is placed flat on the cover surface. If the O-ring is twisted, fluid leaks may occur. 7.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 284: Front Gearcase Diagnosis
Brown/White wires that feed the hub coil wires. new Cover Plate Assembly. There should be a minimum of 11.80-12.0 Volts present for proper operation. AWD Coil Applied Battery Voltage: 11.80-12.0 Vdc 7.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 285: Setting Ring Gear Backlash Non Adc
Re-apply Loctite 262™ onto the bottom screw threads. 3. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. 7.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 286 4 times (1 revolution of ring gear). 6. The gearcase may be filled with the recommended amount of lubricant once gearlash procedure is complete. 7.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 287: Front Gearcase - Centralized Hilliard Adc (6X6)
“wedge” themselves between the external cam / ring gear and output hubs that link both front axles, resulting in true all wheel drive. 7.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 289 Pinion Cover Assembly Hose Clamp Retaining Ring Backlash Adjustment Assembly Pinion Gear Assembly Plastic Clip Fill Plug Drain Plug Reservoir Ring Gear Piston Assembly 1/4-20 Screws 7.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 290: Adc Operation
ADC’, a 12 Vdc current is present at the input shaft coil rear wheel drive until the next deceleration. (1). Operation is controlled by the ECU grounding and ungrounding the coil. The coil’s magnetic field attracts a 7.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 291: Front Gearcase Diagnosis
Brown/White wires that feed the hub coil wires. new Cover Plate Assembly. There should be a minimum of 11.80-12.0 Volts present for proper operation. AWD Coil Applied Battery Voltage: 11.80-12.0 Vdc 7.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 292: Coil Testing
Refer to the following tests in Chapter 10. rollers are able to slide up and down and in and out freely within the roll cage sliding surfaces. 7.26 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 293: Adc Differential Hydraulic Circuit Bleeding
Decreased performance may be encountered with inadequate bleed of the hydraulic circuit. 5. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Polaris ADC oil. 6. Locate bleeder valves found on either side of differential and remove the protective caps.
Page 294 IMPORTANT: Excessive debris in the oil and/or noise coming from front drive deceleration are key indicators of clutch pack failure. Replace clutch as an assembly if found to be worn or damaged. 7.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 295 9. Thoroughly clean all parts. pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation. NOTE: See “Front Gearcase Diagnosis”, page 7.25 7.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 296 See the “FRONT GEARCASE ASSEMBLY” in this chapter for details on backlash setting. 14. Remove the bolts retaining the input shaft cover and pinion gear assembly. 7.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 297 Replace the input shaft cover O-ring (3) prior to reassembly. 18. Remove the snap ring retaining the input shaft assembly. 20. Inspect the input shaft bushing. Replace case if worn. 7.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 298: Adc Gearcase Piston Replacement Procedure
(circled) to force piston up and out of the case. (See photo) 2. Repeat procedure for the other piston. (See photo) 7.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 299 The piston is fully seated and located in the pin bosses when the piston surface is just below the cavity edge. 7.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 300 Verify that the o-rings are seated properly and that no o-ring shavings exist outside of the piston area, which is an indication of damage during installation. 7.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 301: Assembly
(2) prior to reassembly. 6. Install the splined armature plate (2). 4. Install the snap ring retaining the input shaft assembly. 7.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 302 NOTE: Ring gear backlash (2) is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed. 7.36 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 303 NOTE: Align output hub in the ring gear gear. recesses. during installation. 12. Install new cover o-ring and ADC passage o-ring (arrow) on the gear case. 7.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 304: Setting Ring Gear Backlash
15. Install a new passage o-ring (dotted circle) on the screw threads. gearcase and install the piston pump assembly. Torque the screws to specification. Pump Assembly Screw: 17-23 in-lbs (1.9-2.5 Nm) 7.38 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 305 4. Set the gearcase upright. Rotate the input shaft at rotates smoothly 4 times (1 revolution of ring gear). least 4 times. This ensures the ring gear completes one full rotation. 7.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 306: Middle Gearcase (6X6)
Some prying and tapping with a soft-face hammer may be required. Use care not to damage other components. 7.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 307 7. Inspect the gears for abnormal wear, broken, or IMPORTANT: Replace bearings upon removal, chipped teeth. Spin the bearings and check for as removal can cause permanent internal smoothness. Replace bearings if needed. damage. 7.41 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 308 . 11. Remove the pinion gear bearing using a bearing splitter and puller. IMPORTANT: Replace bearings upon removal, as removal can cause permanent internal damage. 7.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 309 Inspect the pinion gear for abnormal wear, broken, or chipped teeth. Spin the bearing and 15. Remove remaining seals from the gearcase. check for smoothness. Replace if required. 7.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 310: Reassembly
7. Install the ring gear into the left case half. Some tapping with a soft-faced hammer may be required. Use care to avoid damage to the seal lip on installation. 7.44 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 311 Crankcase Sealant (PN 2871557) to the sealing surface. Gearcase Capacity Requirement - Rebuild Only 18.5 oz (550ml) Drain / Fill Plug: 16 ft-lbs (22 Nm) 7.45 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 312: Installation
Steel Wheels - 27 ft-lbs (37 Nm) Aluminum Wheels - 30 ft-lbs + 1/4 turn (41 Nm) + 1/4 turn 5. Re-install gearcase vent line. 6. Refill the gearcase with Polaris Lubricant (PN 2871653). Refer to Chapter 2. 7.46 9924864 - 2012-2014 SPORTSMAN 800 / 6X6...
Page 313: Middle Gearcase Exploded View
O-ring Cover Shaft Seal Thrust Button Gear, Drive Bolt Shim Gear, Driven Seal Dowel Pin Shaft, Pinion Seal Vent Tube Gear, 31T Bearing Flange Bolt Bearing 7.47 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 314: Front Drive (Cv) Shaft
7. Remove the two brake caliper attaching bolts. CAUTION Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line. 7.48 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 315 10. Remove lower A-arm from ball joint using a ball joint fork tool. 11. Pull strut assembly out while pivoting the CV drive shaft away until it clears the strut assembly. 7.49 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 316: Installation
Front Hub Retaining Nut: 60 ft-lbs (91 Nm) 5. Install brake caliper and tighten bolts to specification. Refer to Chapter 9. Brake Caliper Fastener: 18 ft-lbs (24 Nm) 7.50 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 317: Rear Hub
7. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. 10. Remove upper control arm bolt as shown. 7.51 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 319: Assembly
1. Support bottom of bearing carrier housing. 2. Start bearing in housing. CAUTION Use an arbor press only on the outer race to avoid bearing damage. 4. Install snap ring into groove. 7.53 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 320: Installation
5. Pull drive shaft outward and install hub onto driveshaft splines. Apply anti-seize to the splines. 6. Install cone washers with domed side facing outward. 7. Install retainer nut, wheel and wheel nuts. 7.54 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 321: Rear Drive (Cv) Shaft
CV joint failure will occur. 3. Pull sharply outward remove shaft from transmission. Install a new compression ring and apply an anti-sieze compound to the splines upon assembly. 7.55 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 322: Installation
Install new cotter pin and hub cap. Rear Hub Nut: 80 ft-lbs (109 Nm) 6. Install brake caliper and tighten bolts to specification. Refer to Chapter 9. 7.56 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 323: Rear Gearcase (6X6)
9. Pull gearcase out the rear of the vehicle. Some prying and tapping with a soft-face hammer may be required. Use care not to damage other components. 7.57 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 324 Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed. 6. Remove the input shaft cover and the pinion shaft from the gearcase housing. See next page. 7.58 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 325: Reassembly
2. Replace all O-rings, seals, and worn components. Input Cover Bolt: 25 ft-lbs (34 Nm) 4. Install the original shim (s), thrust button, and thrust button shims into the gearcase cover. 7.59 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 326: Installation
Wheel Nut (Aluminum): 30 ft-lbs (41 Nm) + 1/4 turn 5. Re-install gearcase vent line. Cover Bolt: 6. Refill the rear gearcase with Polaris Premium 25 ft-lbs (34 Nm) Gearcase Lubricant (PN 2871653). Refer to the “REAR GEARCASE LUBRICATION” procedure in Chapter 2.
Page 328: Cv Drive Shaft Service
FINAL DRIVE CV DRIVE SHAFT SERVICE Drive Shafts and Propshafts Components NOTE: Refer to your parts manual for the proper replacement parts. 7.62 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 329: Drive Shaft And Cv Joint Handling Tips
IF CV JOINT CLEANED, recommended amount of grease to the joint in addition to the grease pack supplied with boot kit. 7.63 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 331 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 7.65 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 332: Outer Cv Joint / Boot Replacement
6. Make sure the circlip is on the shaft and not left in the joint. 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 7.66 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 333 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 7.67 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 334: Inner Plunging Joint / Boot Replacement
3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. Axle Boot Clamp Tool 8700226 or PU-48951 7.68 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 336 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make Axle Boot Clamp Tool sure the boot is not dimpled or collapsed. 8700226 or PU-48951 7.70 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 338: Prop Shaft - Front Or Rear
2. For installation, reverse the removal procedure. NOTE: If removing rear propshaft, loosening and/or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal. 7.72 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 339: U-Joint Service
2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 7.73 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 342: General Information
2871699 (Part of 2871702 Kit) Rear Driveshaft Seal Guide Bearing Seal Driver (50 mm) 2871282 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ Lubrication Refer to Chapter 2 for transmission lubricant type and capacity. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6...
Page 343: Transmission Service (4X4)
TRANSMISSION TRANSMISSION SERVICE (4X4) Transmission Frame Mounts Transmission Frame Mount Locations A = Frame Long Bolts: 37 ft-lbs (50Nm) B = Side Fasteners: 37 ft-lbs (50Nm) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 344: Transmission Upper Frame Mount
TRANSMISSION Transmission Upper Frame Mount Transmission Upper Frame Mount Location A = Bracket-to-Frame Fasteners: 20 ft-lbs (27Nm) B = Bracket-to-Transmission Bolt: 37 ft-lbs (50Nm) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 345: Transmission Rear Stabilizer Mounts
Transmission Rear Stabilizer Mounts Transmission Rear Stabilizer Mounts A = Stabilizer-to-Frame Fasteners: 20ft-lbs (27Nm) B = Stabilizer-to-Transmission Bolt: 37 ft-lbs (50Nm) C = Stabilizer-to-Transmission Fasteners: 37 ft-lbs (50Nm) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 346: Transmission Control Arm Bracket Mounts
3. Remove gear selector handle by prying the cover off and removing the retaining screw. A = Bracket Mounting Bolts: 37 ft-lbs (50Nm) B = Bracket Fasteners: 37 ft-lbs (50Nm) 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 347: Transmission Removal
Transmission Removal Transmission Installation 1. Place vehicle in “park”. Raise and securely support 1. Apply Polaris Premium All Season Grease (PN rear of ATV under the frame. Remove both rear 2871423) to splines of front output shaft ,install new wheels.
Page 348: Troubleshooting Checklist
Rear Wheel Nut Torque Refer to Chapter 2 14. With the ATV on level ground, add Polaris AGL Gearcase Lubricant to the proper level. See Chapter proper fill procedures Torque Specifications. Polaris AGL Gearcase Lubricant (PN 2878068) (12 oz.)
Page 349: Transmission Disassembly
6. Remove the sector cover bolts (E) and remove the sector cover (F). NOTE: Removal can be aided by using your thumbs to press down on the shafts while pulling up the cover with your fingers. 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 350 12. Note location of chain tensioner cam (N). If fully extended, chain is worn beyond service limit and should be replaced along with the chain tensioner shoe. 8.10 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 351 (U). 17. Remove the shift drum (V) from the gearcase by moving the drum up and to the right to clear the shift shaft. 8.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 352 (see Figure 8-2). 28. Remove the retaining ring, washer, 38T sprocket and needle bearing from the reverse shaft (see Figure 8- 8.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 353 Snorkel Shaft Removal / Disassembly 30. Using a T27 Torx driver, remove the snorkel tube locking screw located inside the gearcase. 8.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 354 35. Remove the snap ring and shim retaining the bearing in the snorkel tube. 38. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 8.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 355: Snorkel / Output Gear Backlash Procedure
5. Install the output gear assembly. Be sure to properly mesh the snorkel shaft bevel gear with the output bevel gear. 8.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 356 Do not overtighten the snorkel tube. Gears should rotate freely without binding. 8. Look down into the gearcase at the snorkel locking screw hole opening to reference your starting point. 8.16 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 357: Transmission Assembly
Snorkel Locking Screw: 8-12 ft-lbs (11-16 Nm) 13. With the snorkel shaft assembly properly installed, remove the (4) Torx screws and remove the output shaft assembly. 8.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 358 Replace the chain if the measurement is longer than the service limit. Silent Chain Service Limit (8 pitch): 3.090” (7.849 cm) 8.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 359 • The differential gear bearing may be lightly tapped into place. The output seal can be installed once the assembly is in place. Output Gear Retaining Screws: 8-12 ft-lbs (11-16 Nm) 8.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 360 Torque the screws to specification. Gearcase Cover Bolts: • Place the spring over the front pin and hook 25-30 ft-lbs (34-41 Nm) the spring leg under the cam. 8.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 361 Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks on the gears as shown. 8.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 362 18. Apply Crankcase Sealant (3-Bond) (PN 2871557) onto the cover and transmission case mating surface. Install the sector cover and torque the bolts to specification. Sector Cover Bolts: 8-12 ft-lbs (11-16 Nm) 8.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 363 20. Install the shift shaft onto the bellcrank end (if removed) and secure with the snap bushing. 21. Install the transmission gear selector switch and secure the switch with the retaining ring. 8.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 364: Torque Specifications
TRANSMISSION TRANSMISSION SERVICE (6X6) Torque Specifications Lubricant / Capacity Use only Polaris recommended products if possible. FT-LBS (IN- COMPONENT LBS.) Transmission Case Bolts 27-34 37-46 (16-30) Oil Deflector Screws 2-3.3 Shift Cover Bolt 6-12 8-16 Specified Lubricant: Bell Crank Nut...
Page 365: Transmission Removal
13. Remove transmission from right side of frame. 9. Remove the PVT outer cover, both drive and driven clutches, and the inner PVT cover (refer to Chapter 8.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 366: Disassembly
(A). NOTE: It may be helpful to place a mark just above the keyed spline. Note the raised edge on the detent gear for reassembly. 8.26 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 367 7. Remove the shift shaft and detent lever. 9. Remove the upper gear cluster and shift forks. You may need to move the assembly back and forth to aid in removal. 8.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 368 13. Remove the park lock engagement dog. Remove the 11. Remove the shift forks from the assembly. Note the wave spring and reverse engagement dog. correct position of each fork. 8.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 369 17. Remove the reverse gear shaft. 15. Remove the snap ring and washer from the reverse shaft. 18. Remove the rest of the bearings from the shafts. 8.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 370 21. Remove the gear, split bearing, and washer from the reverse shaft. 20. Make note of the direction of the gear and hub 22. Slide off the shift dogs and wave springs. location. 8.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 371 25. Remove the pinion shaft retainer plate and the pinion bearing. shaft. 26. Remove the front housing cover screws. 24. Remove bearing and the helical gear. 8.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 372 NOTE: New seals should be installed after the transmission is completely assembled. 34. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. 8.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 373: Assembly
3 steps to specification. NOTE: Verify case locating pins (knock pipes) are in place. Cover Bolt: 27-34 ft-lbs (36.5-46 Nm) Torque in Sequence 8.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 374 6-12 ft-lbs (8-16 Nm) chain. 11. Install a new needle bearing, the low gear, the thrustwasher and the snap ring. A new snap ring is recommended. 8.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 375 NOTE: Use caution when installing the fork, as the spring can easily fall out. Installing the shift rail will aid in keeping the shift forks, shift dogs, and the springs in place. 8.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 377 Grease the o-ring on the end of the shift drum. 29. Torque the remaining bolts to specification. Cover Bolt: 6-12 ft-lbs (12-16 Nm) 8.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 378: Transmission Installation (6X6)
10. Tighten rear gearcase fasteners to specification. Refer to Chapter 7. 11. Install shift switch connector and shift rod. 32. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended 12. Install remaining body panels and fasteners as amount.
Page 379: Troubleshooting
If it functions properly, the problem outside transmission. transmission problems remain, disassemble the transmission and inspect. 8.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 380: Transmission Exploded View (4X4)
TRANSMISSION TRANSMISSION EXPLODED VIEW (4X4) Sportsman Transmission Exploded View (4X4) 8.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 381 Seal Ball Bearing Lockout Disc Input Shaft Magnetic Plug Chain Shift Fork Compression Spring Shift Rail Tensioner Pin Torsion Spring Chain Tensioner Cam Chain Tensioner Shoe 8.41 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 382: Transmission Exploded View (6X6)
TRANSMISSION TRANSMISSION EXPLODED VIEW (6X6) Sportsman Transmission Exploded View (6X6) 8.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 383 Screw (Torque 25-30 ft-lbs) Gear Set, 10 T / 31 T Ball Bearing Spacer Retaining Ring Cover Screw (Torque 6-12 ft-lbs) Gear, 56 T Ball Bearing 8.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 387: Specifications
BRAKES SPECIFICATIONS Special Tools Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ Torque Table TORQUE SPECIFICATIONS TORQUE FT-LBS (IN- ITEM TORQUE NM LBS) Front / Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp Bolts (25 in-lbs) Hand Master Cylinder Reservoir Cover Screws (7 in-lbs) 0.79...
Page 392: Hydraulic Brake System
When servicing Polaris ATV brake systems, use only Polaris DOT-approved brake fluid. WARNING The Polaris disc brake system consists of the following Once a bottle is opened, use what is necessary and components or assemblies: brake lever; master cylinder; hydraulic hose; brake calipers (slave cylinder); brake discard the rest in accordance with local laws.
Page 393: Brake Noise Troubleshooting
(chain, axle, hub, disc or check other sources. wheel) Inspect and repair as necessary Change to a softer or Wrong pad for harder pad (if available) conditions 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 394 BRAKES 5. Begin bleeding procedure with the caliper that is 11. Add Polaris DOT-approved Brake Fluid to MAX level farthest from the master cylinder. Install a box end inside reservoir. wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container.
Page 395 1/2”, (1.3 cm) from handlebar. 16. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. 9.11 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 396: Front Master Cylinder
4. Follow proper bleeding procedures. Check all connections for leaks and repair if necessary. 9.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 397: Front Brake Pads
Remove excess fluid from reservoir as required. 6. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 4. Remove caliper from mounting bracket. 9.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 398: Assembly
If pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. Front Brake Pad Thickness Service Limit: .180” / 4.6 mm 9.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 400: Front Brake Disc
Service Limit: .010” / .254 mm Brake Disc Thickness: Service Limit: .140” / 3.556 mm Brake Disc Thickness Variance Service Limit: .002” (.051 mm) between measurements. 9.16 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 401: Removal / Replacement
Front: 18 ft-lbs (24 Nm) Rear: 27 ft-lbs (36 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 402: Front Caliper
NOTE: Be sure to clean seal grooves in caliper body. 2. Push upper pad retainer pin inward and slip brake pads past edge. Loosen pad adjuster. 9.18 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 403: Inspection
Replace if damage is evident or if worn beyond may drag upon assembly. service limit. 2. Coat piston with clean Polaris DOT-approved Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 404: Installation
4. Perform brake bleeding procedure as outlined earlier in this chapter. 5. Install wheels and torque wheel nuts to specification. Refer to Chapter 2. Brake Caliper Mounting Bolt: 18 ft-lbs (24 Nm) 9.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 405: Rear Brake Pad
5. Push caliper pistons into caliper bore slowly with pads installed. 6. Remove the caliper slide pins and remove the brake pads from the caliper. 7. Clean the caliper with brake cleaner or alcohol. 9.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 406: Rear Pad Installation
Rear Brake Pad Thickness Service Limit: .180” (4.6 mm) 2. Install and tighten the slide pin with a hex wrench. 9.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 407: Brake Burnishing Procedure
Repeat this procedure 10 times. 4. Install the slide bolt snap ring. Torque the slide pin to specification. Caliper Slide Bolt: 30-35 ft-lbs (41-48 Nm) 9.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 408: Rear Caliper
O-rings and replace if necessary. 4. Remove the slide bolt snap rings (A), the slide pins (B), the bracket pad (C), and the brake pads (D). 9.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 409: Assembly
11. Inspect surface of caliper piston for nicks, scratches, Caliper Anvil Bolt: or damage and replace if necessary. 16-18 ft-lbs (22-24 Nm) 9.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 410 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation. 9.26 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 411: Rear Brake Disc
Service Limit: .010” / .254 mm Brake Disc Thickness: Service Limit : .170” (4.318 mm) Brake Disc Thickness Variance: Service Limit: .002” (.051 mm) Between Measurements 9.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 412: Rear Master Cylinder
REAR MASTER CYLINDER Overview Polaris disc brake systems are light weight, low maintenance and perform well in the conditions ATVs routinely encounter. However, there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.
Page 413: Rear Master Cylinder Removal / Installation
5. Reinstall the brake line and torque the banjo bolt to specification depending on the style of fitting. Banjo Bolt: 15 ft-lbs (21 Nm) 6. Perform brake bleeding procedures as outlined in this chapter. 9.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 414 • Worn or damaged master cylinder or components • Improper clearance between lever and switch Lever Vibration • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 9.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 418: General Information
ELECTRICAL GENERAL INFORMATION Special Tools Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 10.4 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 419: Instrument Cluster
INSTRUMENT CLUSTER Overview Introduction Refer To Illustration 1: The Polaris ATV Instrument Cluster is powered by battery voltage (12 Vdc) and requires inputs from the engine RPM, transmission gear, and speed sensor for proper operation. Two harnesses plug into the cluster head;...
Page 420 All related icons will flash, “FUEL” will display in the LCD, and the speedometer needle will blink. If riding, be sure to refuel immediately. 10.6 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 421: Instrument Cluster Diagnostic Mode
9. When desired hour displayed, wait approximately four seconds, until the minute display flashes. 10. When the display stops flashing, the mode has been set. 10.7 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 422 This screen displays the resistance value (in ohms) the AWD coil on models with AWD. being read at the gear switch input of the gauge. 10.8 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 424: Setting A New Service Interval
6. While in the service interval mode, press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center. 10.10 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 425: Efi Diagnostic Mode
EFI module. flashing. The new service interval is now set. Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink code. Screen 6 - Miles/Kilometers: toggle, The display in...
Page 426 4. The word “End” will display after all of the codes have been displayed. NOTE: A list of applicable codes is shown on the next page 10.12 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 427 Pump Relay: Short Circuit to Ground Pump Relay: Short Circuit to Battery Cooling Fan: Open Load Cooling Fan: Short Circuit to Ground Cooling Fan: Short Circuit to Battery END of Check 10.13 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 428: Speedometer Removal
NOTE: Do not remove the rubber grommet in the pod. Only remove the rubber grommet if necessary. The bezel is a snap-on assembly and is a serviceable part. 10.14 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 429: Speedometer Installation
IMPORTANT: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens. 10.15 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 431: Test 2 - No Display / Test 3 - No Reverse Speed Limit
ELECTRICAL TEST 2 - No Display / TEST 3 - No Reverse Speed Limit 10.17 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 433: Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
ELECTRICAL TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor 10.19 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 434: Test 6 (4X4) - Vehicle Speed Sensor
3. Pass a screwdriver back and forth in front of the sensor tip. 4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 10.20 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 435: Test 7 - No Fuel Gauge / Test 8 - Transmission Switch
ELECTRICAL TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch 10.21 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 436: All Wheel Drive (Awd) Coil (4X4)
80% of all electrical issues are caused by bad/failed connections and grounds. Refer to the ADC subsystem diagram located in ‘Wire Diagrams’ at the end of this chapter. 10.22 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 437: Active Descent Control (Adc) Coil (6X6)
• Verify the wiring harness, wiring, connectors, connector pins, grounds and ECU pin locations are undamaged, clean and connect properly. • Verify continuity of wire connections with a known good volt/ohm meter. 10.23 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 438: Cooling System Components
If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 10.24 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 439: Fan Motor Current Draw
5. If the fan motor draws more than 15 Amps, replace the motor. Fan Motor Current Draw: Should Be Less Than 15 Amps NOTE: This fan motor current draw specification only applies to Sportsman EFI models. 10.25 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 441: Throttle Release System (Trs) Switch
ECU. Adjust throttle cable freeplay (TRS switch) and make sure throttle mechanism is functioning properly before testing the switch. Refer to Maintenance Chapter cable adjustment procedure. 10.27 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 442: Charging System
9. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.28 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 443: Alternator Output Test
TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM 3. Set the selector dial to measure AC Voltage. 4. Start the engine and let it idle. 10.29 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 444: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. 10.30 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 445: Relays
Red / White switches, enables power to relay. KEY-ON Battery power supply, Orange / Black switched on by the key and LH control switches, enables power to relay. 10.31 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 446: Fuses/Circuit Breaker
The fuse panel, located next to the ECU, assists with component protection such as the Instrument Cluster/ ECU, EFI system, Chassis Power and Accessories. A 20-amp circuit breaker protects the fan circuit. 10.32 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 447: High Beam Headlight Bulb Replacement
3. Disconnect instrument cluster harnesses from the back of the speedometer. 4. Turn the headlight lamp socket counter-clockwise and remove. 5. Carefully remove headlamp bulb from housing. 10.33 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 448: Headlight Housing Replacement
5 1/ 8”, (13 cm). See illustration. 9. Adjust the headlight aim by turning the adjusting knob. 10.34 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 449: High Beam Headlight Adjustment
On machines with separate low beam lights, the drop should be 8, (20.3 cm) in 25' from the center of the low beam lamp. 5. Adjust beam to desired position. 10.35 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 450: Low Beam Headlight Adjustment
(Brown and Yellow) at back of connector for 12 Volts. 3. Turn ignition and headlight on. If there is no power, continue with checks to the harness and fuses. 10.36 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 451: Brake Light Replacement (4X4)
1. To remove the brake light electrical connector (A) , press in on the tab on the connector to unlock the connector and pull the connector from the bulb assembly. 10.37 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 452: Brake Light Switch (4X4)
Replace switch if there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure. 10.38 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 453: Brake Lamp/Tail Lamp Replacement (6X6)
1/4 turn to lock in place. Refer to the parts manual for the correct bulb part number. 4. Reinstall the tail lamp assembly. Install the screws and tighten sufficiently. 10.39 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 454: Fuel Sender
• Float contact with tank • Bent Float Rod If none of the conditions exists, the sender assembly is faulty. Fuel pump assembly replacement is required. 10.40 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 455: Accessory Power
Orange / White in color. To locate the wires, remove the front cover. The wires will be located in the main wire loom on the right side. NOTE: Refer to the accessory instructions for accessory hook-up and installation. 10.41 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 456: Starter System
• Wire harness, loose connections/pins (including the ECU) leading to and from these components • Proper ground to frame Should all these items be found in working order, the ECU may be at fault. 10.42 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 457: Troubleshooting
Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 10.43 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 458: Voltage Drop Test
“Electric Starter System Testing” in this section to further 2. Remove (+) positive battery from the starter battery test the solenoid. post. 3. Remove the starter from the engine. 10.44 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 459: Starter Installation
Make sure the end washer is positioned properly so that it will hold the lock ring in its groove. 10.45 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 461: Starter System Testing Flow Chart
STARTER SYSTEM TESTING FLOW CHART Flow Chart Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. 10.47 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 462: Battery
Your ATV may have a Conventional Battery or a Sealed Authorized Polaris dealers/distributors are required to Low Maintenance Battery. To identify which type of use the conductance analyzer when testing 12V Polaris battery your ATV has, refer to the illustration below and batteries.
Page 463: Battery Activation (Conventional)
KEEP OUT OF REACH OF CHILDREN. Battery Terminals/Bolts Terminal Preparation Use Polaris corrosion resistant Nyogel grease (PN WARNING 2871329) on battery bolts and terminals when installing a battery. This will help to prevent corrosion and maintain good electrical connection.
Page 465: Conventional Battery Installation
25% Charged less than 1.100 Less than 1.115 0% Charged – – * Measurement at 80° F Subtract .01 from the specific gravity reading at 40° F 10.51 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 466: Battery Load Test
ELECTROLYTE FREEZING POINTS SPECIFIC GRAVITY OF FREEZING POINT ELECTROLYTE 1.265 -75° F 1.225 -35° F 1.200 -17° F 1.150 +5° F 1.100 +18° F 1.050 +27° F 10.52 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 467: Charging Procedure
The battery should be checked every 3 months. 2. Check the voltage with a voltmeter or multimeter. A fully charged battery should be 12.8 V or higher. 10.53 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 468: Low Maintenance Battery Charging
50-75% 5-11 Hours At least 13 hours, 11.5-12.0 Needs Charge 25-50% verify state of charge 11.5 V At least 20 Needs Charge 0-25% or less hours 10.54 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 469: Low Maintenance Battery Inspection / Removal
* Measurement at 80° F terminals and bolt threads with Nyogel® Grease (PN 2871329). NOTE: Subtract .01 from the specific gravity reading at 40° F. 4. Reinstall the holder strap. 10.55 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 470: Low Maintenance Battery Load Test
9.5 volts. 4. If the beginning voltage is 12.8 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery. 10.56 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 471: Low Maintenance Battery Off-Season Storage
ELECTROLYTE FREEZING POINTS SPECIFIC GRAVITY OF FREEZING POINT ELECTROLYTE 1.265 -75° F 1.225 -35° F 1.200 -17° F 1.150 +5° F 1.100 +18° F 1.050 +27° F 10.57 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 472: Troubleshooting Diagrams
NOTE: Illustrations are representative and may not apply to all models. Refer to the wire diagrams for the correct wire circuit and technical information (if applicable). All Wheel Drive - EFI Charging Circuit - EFI 10.58 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 477 Digital Wrench Communication Errors ..... 4.34 Brake, Master Cylinder Removal......9.12 Digital Wrench Diagnostic Software ......4.33 Brake, Rear Auxiliary Brake........9.29 Digital Wrench Versions ......... 4.33 IX.1 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 478 Engine Gear(s) Removal ........3.42 Front Cover Removal / Installation ......5.5 Engine Gears, Installation ........3.53 Front CV Axle Installation ........7.50 Front CV Axle Removal .......... 7.48 IX.2 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 479 PVT Troubleshooting ..........6.48 Ignition Coil Test ............ 4.32 PVT, Drive Clutch Disassembly....... 6.23 Inner Plunging Joint / Boot Replacement ....7.68 PVT, Drive Clutch Reassembly ....... 6.29 IX.3 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 480 Specification, Wheel Toe-Out........2.32 Transmission Assembly ......... 8.33 Specifications, Body and Steering Torque Values ..5.2 Transmission Disassembly ........8.26 Specifications, Brake Component Service Limits..9.3 IX.4 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 481 VIN Number ............1.2 Voltage Drop Test ..........10.44 Wheel Alignment ........... 2.32 Wheel Installation ..........2.38 Wheel Removal ............. 2.38 Wire Diagrams, Electrical ........10.58 IX.5 9924864 - 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc.
Page 482 2012-2014 SPORTSMAN 800 EFI PAGE 1 OF 2 Located By Battery...
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Page 484 2012-2014 SPORTSMAN 800 EFI 6X6 PAGE 1 OF 2 Located By Battery...
Page 485 2012-2014 SPORTSMAN 800 EFI 6X6 PAGE 2 OF 2...

Polaris Sportsman 800 EFI 4x4 2012 Service Manual

Chapter 1 1 General Information

Chapter 2 Maintenance

Chapter 3 Engine

Chapter 4 Fuel System - General

Chapter 5 Body / Steering / Suspension

Chapter 6 Clutching

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris Sportsman 800 EFI 4x4 2012

Summary of Contents for Polaris Sportsman 800 EFI 4x4 2012