Table of Contents
Advertisement
Quick Links
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
utility vehicles
®
• Victory Motorcycles
®
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the POLARIS Service Manual
and should be performed only by a factory-certified Master Service
Dealer
(MSD) technician. Please see your dealer for all of your service
®
needs during (and after) the warranty period.
For more information about POLARIS, visit us online at
www.polarisindustries.com.
1
Advertisement
Table of Contents
Related Manuals for Polaris SPORTSMAN FOREST 800 Series
Summary of Contents for Polaris SPORTSMAN FOREST 800 Series
- Page 1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ®...
- Page 2 POLARIS, THE WAY OUT, SPORTSMAN and BIG BOSS are registered trademarks of POLARIS Industries Inc. Copyright 2011 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
-
Page 3: Table Of Contents
Specifications ......128 POLARIS Products..... 130 Warranty . -
Page 4: Introduction
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury. - Page 5 WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.
-
Page 6: Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. -
Page 7: Safety
SAFETY Safety Training Never operate this vehicle without proper instruction. Take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com. - Page 8 Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
-
Page 9: Eye Protection
Equipment Modifications We strongly recommend that consumers do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehi- cle, or make any other modifications to the vehicle for these purposes. -
Page 10: Operating Without Instruction
Even though a child may be within the recommended age group for operating some POLARIS vehicles, he/she may not have the skills, abilities, or judgment needed to operate this vehicle safely and could be susceptible to accident or injury. -
Page 11: Safety Warnings
SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- eling is performed or where gasoline is stored. -
Page 12: Protective Apparel
SAFETY Safety Warnings Protective Apparel Riding on this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). -
Page 13: Operating On Pavement
SAFETY Safety Warnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn. Avoid operating the vehicle on pavement. The tires are designed for off-road use. -
Page 14: Turning Improperly
SAFETY Safety Warnings Physical Control of the Vehicle Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the vehicle. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. -
Page 15: Descending Hills Improperly
SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. -
Page 16: Stalling While Climbing A Hill
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. -
Page 17: Operating On Steep Hills
SAFETY Safety Warnings Operating on Steep Hills Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the vehicle or for your abilities. Never operate the vehicle on hills steeper than 25 degrees. Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or... -
Page 18: Skidding Or Sliding
SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. -
Page 19: Improper Cargo Loading
SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this vehicle. • Cargo should be properly distributed and securely attached. -
Page 20: Operating Through Deep Water
SAFETY Safety Warnings Operating Through Deep Water Operating the vehicle through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the vehicle through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 59):... -
Page 21: Operating A Damaged Vehicle
SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills. -
Page 22: General Warning
If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. General Warning... -
Page 23: Reverse Override Warning
SAFETY Safety Labels and Locations Reverse Override Warning General Tire Pressure/Load Warning Warning Front Rack Warning Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. •... - Page 24 SAFETY Safety Labels and Locations Age 16 Warning Container/No Passenger Warning Clutch Cover Warning Container/No Passenger Warning WARNING Remove flammable containers from box before refueling. WARNING • Passengers can be thrown off. This can cause serious injury or death. •...
-
Page 25: Age 16 Warning
SAFETY Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. Clutch Cover Warning WARNING •... -
Page 26: Features And Controls
FEATURES AND CONTROLS Switches Engine Headlight Stop Switch Switch Switch Main Key Switch Mode/Reverse Override Winch Switch Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, release the throttle and depress the override button. -
Page 27: Engine Stop Switch
FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. - Page 28 Engine speed returns to idle when the lever is released. This vehicle is equipped with POLARIS Electronic Throttle Con- trol (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
-
Page 29: Brake Systems
FEATURES AND CONTROLS Brake Systems WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the rear brake. Do not aggressively apply the rear brake when going forward. - Page 30 FEATURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti- vated disc brakes. Always test brake lever travel and master cylinder fluid level before riding.
- Page 31 FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
-
Page 32: Parking Brake
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in park. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. -
Page 33: Fuel Tank Cap
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located Gear on the right side of the vehicle. Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. -
Page 34: All Wheel Drive (Awd) System
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the 4X4 (AWD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline. -
Page 35: All Wheel Drive System
FEATURES AND CONTROLS All Wheel Drive System Engaging AWD The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable AWD until the engine RPM is below 3100. Once enabled, AWD remains enabled until the 4X4 switch is turned off. -
Page 36: Engaging Active Descent Control
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:... -
Page 37: Instrument Cluster
FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. -
Page 38: Rider Information Center
If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear shifter position. - Page 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the vehicle.
-
Page 40: Diagnostic Mode
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. - Page 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all- wheel-drive coil.
- Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.
- Page 43 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. See page 45 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
- Page 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
- Page 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery...
-
Page 46: Operation
Break-In Period The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gaso- line. No single action on your part is as important as following the pro- cedures for a proper break-in. - Page 47 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 78. Add oil if necessary to maintain the level between the safe and add marks. 3.
- Page 48 Ensure proper operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced...
-
Page 49: Safe Operation Practices
OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle. -
Page 50: Trail Etiquette
Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. -
Page 51: Starting The Engine
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. - Page 52 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.
-
Page 53: Turning The Vehicle
OPERATION Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction slightly. -
Page 54: Driving On Slippery Surfaces
OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid skid Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. -
Page 55: Driving Uphill
OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. - Page 56 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.
-
Page 57: Driving Downhill
OPERATION Driving Downhill 25 Maximum When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. Avoid steep hills (25 maximum). 3. Shift body weight uphill. 4. - Page 58 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.
-
Page 59: Driving Through Water
OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Fol- low these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual Maximum Depth... -
Page 60: Driving Over Obstacles
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. -
Page 61: Driving In Reverse
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. -
Page 62: Hauling Cargo
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: •... - Page 63 Never install a hitch longer than 8.25" (21 cm). Never install automotive accessories on your POLARIS vehicle. Always install POLARIS-approved (or equivalent) accessories designed for use on this vehicle.
-
Page 64: Dumping Cargo
OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check cargo distribution. If cargo has shifted to the rear of the box, Latch exercise caution. -
Page 65: Parking On An Incline
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. -
Page 66: Winch Guide
WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and oper- ating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people. Winch Safety Precautions 1. -
Page 67: Winch Cable Care
WINCH GUIDE Winch Cable Care 1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement cables) must be re- spooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage. - Page 68 WINCH GUIDE Winch Preparation and Inspection DANGER Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.
-
Page 69: Winch Rigging
WINCH GUIDE Winch Rigging WARNING Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch. 1. -
Page 70: Winch Operation
WINCH GUIDE Winch Operation NOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating. 1. Use common sense. 2. Take your time. 3. Think through the situation. 4. Pay attention to what is going on when you are winching. 5. - Page 71 WINCH GUIDE Winch Operation 13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.
-
Page 72: Emission Control Systems
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Exhaust Emission Control System Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. -
Page 73: Maintenance
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 134. - Page 74 Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe ...
- Page 75 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Air filter, Weekly Inspect; replace as needed main element Brake pad wear 10 H Monthly 60 (100) Inspect periodically Engine oil change 20 H 125 (200) Perform a break-in oil change...
- Page 76 Inspect periodically; adjust when parts are replaced Auxiliary brake Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. Have an authorized POLARIS dealer perform these services.
-
Page 77: Lubrication Recommendations
See page 84. gear lube) ADC Fluid Demand Drive PLUS Fluid See page 86. Front Prop Shaft Yoke POLARIS Premium U-Joint Grease fittings (3 pumps maxi- Lube mum) every 500 miles, before long periods of storage, or after pres- sure washing or submerging ... -
Page 78: Engine Oil
POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. -
Page 79: Oil And Filter Change
7. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter- clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. - Page 80 MAINTENANCE Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 11. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.
-
Page 81: Oil Check
ATV behind the footwell. The drain plug is located on the bottom left side of the gearcase. POLARIS recommends the use of Fill Level POLARIS AGL PLUS Transmis- Drain Plug sion Fluid for this transmission. -
Page 82: Demand Drive Capacities
Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 73. We rec- ommend the use of POLARIS Demand Drive PLUS Fluid. Use of other fluids may result in improper operation of components. See page 130 for the part numbers of POLARIS products. -
Page 83: Fluid Change
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely. 4. -
Page 84: Rear Gearcase Oil
The drain plug is located Drain Plug on the bottom of the gearcase. We recommend the use of POLARIS ATV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 130 for the part numbers of POLARIS products. - Page 85 Periodic Mainte- nance Chart beginning on page 73. We recommend the use of POLARIS ATV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 130 for the part numbers of POLARIS products.
- Page 86 Periodic Maintenance Chart beginning on page 73. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of POLARIS Demand Drive PLUS Fluid. See page 130 for the part numbers of POLARIS products.
- Page 87 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).
-
Page 88: Cooling System
Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use. -
Page 89: Radiator Coolant
Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair. - Page 90 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.
-
Page 91: Toe Alignment
1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service. -
Page 92: Side Panel Removal
Steering Assembly The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. -
Page 93: Wheel Removal
Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized POLARIS dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in park. -
Page 94: Wheel Installation
MAINTENANCE Tires Wheel Installation 1. Place the transmission in park. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. -
Page 95: Air Filter
MAINTENANCE Air Filter 1. Remove the seat. Pre-Filter 2. Release the air box cover clips, and remove the air box cover. Main Filter 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. -
Page 96: Fuse Replacement
MAINTENANCE Fuse Replacement Fuse Feature Supported Speedometer Electronic Fuel Injection (Main Fuse) Ignition, Lighting Accessories, 12V Power Receptacle If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. - Page 97 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Upper Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers.
-
Page 98: High Beam Adjustment
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in park. 25 ft. -
Page 99: Low Beam Adjustment
MAINTENANCE Lights Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or down- ward. 3. Tighten the screw. -
Page 100: Headlight Housing Replacement
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. -
Page 101: Lower Headlamp Replacement
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. Harness 4. -
Page 102: Spark Plugs
Refer to the specifications section beginning on page 128 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft. - Page 103 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white.
-
Page 104: Vehicle Immersion
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. -
Page 105: Spark Arrester
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. -
Page 106: Pvt System
• See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation. -
Page 107: Pvt Operation
MAINTENANCE PVT System PVT Operation The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt. -
Page 108: Pvt Drying
MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the tempera- ture inside the clutch cover greatly extends the life of the PVT compo- nents (belt, cover, etc.). - Page 109 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. WARNING Battery electrolyte is poisonous.
-
Page 110: Battery Removal
MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the vehicle. Be careful not to tip a conven- tional battery sideways, which could spill electrolyte. -
Page 111: Battery Installation
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 113 before installing the battery. -
Page 112: Battery Storage
POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. - Page 113 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 110. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
- Page 114 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
-
Page 115: Cleaning And Storage
Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. -
Page 116: Washing The Vehicle
Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. - Page 117 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
-
Page 118: Storage Tips
See page 115. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. -
Page 119: Fluid Levels
5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protec- tive film of fresh oil. 6. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline. -
Page 120: Battery Maintenance
Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensa- tion, and may promote corrosion and oxidation. -
Page 121: Transporting The Vehicle
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. -
Page 122: Adjustments
Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod. - Page 123 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar.
-
Page 124: Troubleshooting
PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to... - Page 125 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
- Page 126 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
-
Page 127: Engine Overheating
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug... -
Page 128: Specifications
Steering System Akerman Principle, with handlebar controls Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 6.1" (15.5 cm) travel... - Page 129 SPECIFICATIONS SPORTSMAN FOREST 800 6X6 Transmission Automatic PVT with E-Z Shift H/L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.11:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 Tires/Pressure, Front Off Road Style, Deep Tread Design Size 25x8-12 / 7 psi (48.3 kPa) Tires/Pressure, Center Off Road Style, Deep Tread Design...
-
Page 130: Polaris Products
Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger... -
Page 131: Warranty
WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that... - Page 132 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • Wheels and tires •...
- Page 133 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA- TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
-
Page 134: Maintenance Log
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS... - Page 135 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
- Page 136 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
-
Page 137: Index
INDEX Accessories ....120 Demand Drive Capacities ..82 Active Descent Control Fluid . . . 86-87 Demand Drive Fluid . -
Page 138: Index
Instrument Cluster ... . 37-45 Polaris Product List ... . . 130 Polishing the Vehicle... . 116 Pre-Ride Checklist. - Page 139 INDEX Safe Operation Practices ..49 Taillight..... . 101 Safety Labels....22-25 Throttle Body Adjustment .