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A12MH76AX
Polaris A12MH76AX Manuals
Manuals and User Guides for Polaris A12MH76AX. We have
1
Polaris A12MH76AX manual available for free PDF download: Service Manual
Polaris A12MH76AX Service Manual (485 pages)
6X6
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 55.23 MB
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Model Information
8
Model Number Designation
8
Vehicle Identification Number (Vin) Designation
8
Engine Number Designation
9
Vin and Engine Serial Number Location
9
Transmission Serial Number Location
10
Sportsman 800 Efi 4X4 Specifications
11
2012-2014 Sportsman 800 Efi
11
Sportsman 800 Efi Big Boss 6X6 Specifications
13
2012-2014 Sportsman 800 Efi Big Boss 6X6
14
Publications / Paint Codes / Keys / Tools
15
Publications
15
Paint Codes
15
Special Tools
16
Replacement Keys
16
Misc. Numbers/Charts
17
Conversion Table
17
Sae Tap / Drill Sizes
18
Metric Tap / Drill Sizes
18
Standard Bolt Torque Specification
19
Metric Bolt Torque Specification
19
Decimal Equivalents
20
Chapter 2 Maintenance
21
Maintenance
23
Overview
23
Special Tools
23
Periodic Maintenance Chart
24
Lubricants / Service Products
27
Polaris Lubricants, Maintenance and Service Products
27
Lubrication / Fluids
28
Pre-Ride / Daily Inspection
28
Lubrication / Grease Points (4X4)
28
Lubrication / Grease Points (6X6)
29
Engine Oil Level
30
Oil/Filter Change
31
Front Gearcase Lubrication (4X4)
32
Front Gearcase Lubrication (6X6)
33
Adc Differential Hydraulic Circuit Fluid Change (6X6)
34
Transmission Lubrication (4X4)
35
Transmission Lubrication (6X6)
36
Middle Gearcase Lubrication (6X6)
37
Rear Gearcase Lubrication (6X6)
38
Vehicle Inspection
39
Shift Link Rod Inspection (4X4)
39
Shift Link Rod Inspection (6X6)
39
Throttle Inspection
39
Throttle Cable / Throttle Release System (Trs Switch) Adjustment
40
Fuel System
40
Vent Lines
40
Compression Test
41
Engine Mounts
41
Spark Plug
42
Battery Maintenance
43
Cooling System
44
Coolant Strength / Type
44
Cooling Hoses
44
Radiator
44
Cooling System Pressure Test
44
Reservoir Level Inspection
45
Radiator Coolant Level
45
Radiator/Grill Screen
46
Air Filter/Pre-Filter Service
47
Air Box Sediment Tube
48
Engine Breather Hose
48
Pvt Inspection / Drying Procedure
49
Engine Ground
49
Camber/Caster
50
Steering Inspection
50
Tie Rod / Steering
51
Toe Alignment
52
Wheel Alignment
52
Exhaust Pipe
53
Brake System Inspection
54
Auxiliary Brake Testing
55
Brake Hose Inspection
55
Brake Pads
55
Auxiliary Brake Adjustment
56
Front Suspension
56
Rear Suspension
56
Suspension: Spring Preload Adjustment
56
Atv Controls
57
CV Shaft Boot Inspection
57
Wheel Inspection
57
Frame, Nuts, Bolts, Fasteners
58
Wheel Installation
58
Wheel Removal: Front or Rear
58
Tire Inspection
59
Tire Pressure
59
Chapter 3 Engine
61
Crankcase Exploded Views
63
Specifications
63
Engine Fastener Torque Patterns
70
Torque Specifications
71
800 EFI Engine Service Specifications
72
General Engine Service
76
Accessible Components
76
Piston Identification
76
Cooling System Specifications
76
Cooling System Pressure Test
77
Coolant Air Bleeding Procedure
77
Engine Removal (Typical)
78
Engine Installation Notes
79
Cylinder Hone Selection and Honing Procedure
80
Honing to Deglaze
81
Cleaning the Cylinder after Honing
81
Oil Flow Chart
82
Engine Lubrication Specifications
83
Oil Pressure Test
83
Engine Disassembly and Inspection
84
Cylinder Head Assembly Exploded View
84
Rocker Arms
85
Push Rods
85
Cylinder Head Removal
86
Cylinder Head Inspection
86
Cylinder Head Warp
86
Valve Seal/Spring Service (on Engine)
87
Cylinder Head Disassembly
87
Valve Inspection
89
Combustion Chamber
90
Valve Seat Reconditioning
90
Cylinder Head Reassembly
93
Valve Sealing Test
94
Cylinder Removal
94
Valve Lifter Removal/Inspection
95
Piston Removal
96
Cylinder Inspection
97
Piston-To-Cylinder Clearance
98
Piston/Rod Inspection
99
Piston Ring Installed Gap
99
Starter Drive/Bendix Removal Inspection
100
Flywheel / Stator Removal / Inspection
101
Engine Crankcase Disassembly / Inspection
102
Camshaft Inspection
111
Engine Reassembly
113
Crankcase Reassembly
113
Flywheel / Stator Installation
126
Cylinder Head Installation
127
800 Efi Exhaust System
131
Exhaust Layout
131
Troubleshooting
132
Engine
132
Cooling System
133
Chapter 4 Fuel System - General
135
General Information
137
Service Notes
138
Efi System Exploded View
139
Efi System Component Locations
140
Diagnostic Connector and Fuses
141
Fuel Tank Assembly
142
Fuel Lines - Quick Connect
143
Electronic Fuel Injection
144
Principal Components
144
Efi Operation Overview
144
Initial Priming / Starting Procedure
145
Electronic Control Unit (Ecu)
146
Operation Overview
146
Ecu Service
147
Ecu Replacement
147
Fuel Pump
148
Operation Overview
148
Fuel Pump Test
148
Fuel Pump / Tank Assembly Replacement
149
Fuel Sending Unit
151
Fuel Sending Unit Test
151
Fuel Pump Replacement
152
Fuel Pressure Regulator
155
Operation Overview
155
Fuel Pressure Regulator Test
155
Fuel Pressure Regulator Replacement
155
Fuel Tank Vent Routing
155
Fuel Tank Vent Hose Routing
155
Fuel Injectors
156
Operation Overview
156
Fuel Injector Service
156
Fuel Injector Replacement
157
Crankshaft Position Sensor (Cps)
158
Operation Overview
158
Crankshaft Position Sensor Test
158
Crankshaft Position Sensor (Cps) Replacement
159
Temperature / Barometric Air Pressure Sensor (T-Bap)
160
Operation Overview
160
Temperature and Barometric Air Pressure Sensor Test
160
Temperature and Barometric Air Pressure Sensor Replacement
160
Throttle Position Sensor (Tps)
161
Operation Overview
161
Tps Learn Function
161
Throttle Position Sensor Test
161
Throttle Position Sensor Replacement
162
Throttle Position Sensor Adjustment
163
Engine Temperature Sensor
164
Operation Overview
164
Engine Temperature Sensor Test
164
Engine Temperature Sensor Replacement
164
Ignition Coil
165
Operation Overview
165
Ignition Coil / Ht Lead Replacement
165
Ignition Coil Tests
166
Digital Wrench® Operation
167
Digital Wrench® Diagnostic Software Overview
167
Special Tools (also Refer to Page 3.2)
167
Diagnostic Software Version
167
Guided Diagnostic Available
167
Digital Wrench® Communication Errors
168
Digital Wrench® - Diagnostic Connector
168
Digital Wrench® Serial Number Location
169
Digital Wrench® Version and Update
169
Digital Wrench® Updates
170
Digital Wrench® Feature Map
172
Ecu Replacement
173
Engine Controller Reprogramming (Reflash)
173
Troubleshooting
177
Diagnostics Using "Blink Codes
177
Efi Circuit - Power
178
Efi Circuit - Crank Position Sensor
178
Efi Circuit - Fuel Pump
179
Efi Circuit - Throttle Position Sensor
179
Efi Circuit - Temperature - Barometric Air Pressure Sensor
180
Efi Circuit - Engine Temperature
180
Efi Circuit - Malfunction Indicator Light
181
Efi Troubleshooting
182
Chapter 5 Body / Steering / Suspension
183
General Information
184
Multi-Function Pliers
184
Torque Specifications
184
Decal Replacement
185
Body
186
Side Panel Removal
186
Front Storage Box Lid / Front Rack and Access Panel Removal / Installation
187
Foot Well Removal / Installation
188
Front Bumper Removal / Installation
188
Mud Guard Removal / Installation
189
Front Fender Removal/Installation
190
Front Rack / Storage Box Lid Assembly (4X4 and 6X6)
191
Front Cab Assembly (4X4 and 6X6)
192
Front Bumper Assembly (4X4 and 6X6)
193
Rear Rack Assembly (4X4)
194
Rear Cab and Seat Assembly (4X4)
195
Rear Storage Box Assembly (4X4)
196
Headlight Pod Exploded View
197
Winch and Front Bumper Mounting (4X4 and 6X6)
198
Rear Fender Panel Removal / Installation (6X6)
199
Rear Body Assembly Exploded View (6X6)
200
Frame / Bumper / Front Rack (6X6)
201
Steering
202
Handlebar Block Installation Procedure
202
Steering / A-Arm Exploded View
203
A-Arm Replacement
204
Ball Joint Replacement
205
Steering Post Removal
206
Steering Post Assembly
207
Suspension
208
Front Strut Cartridge Replacement
208
Strut Assembly
209
Rear Suspension Exploded View (4X4)
210
Torsion Bar Exploded View (4X4)
211
Rear / Middle Suspension Exploded View (6X6)
212
Rear Torsion Bar Assembly (6X6)
213
Cargo Box 6X6
214
Removal / Installation (6X6)
214
Chapter 6 Clutching
217
Clutching Charts
219
Pvt System Fastener Torques
219
Pvt System Overview
219
Special Tools and Supplies
219
Drive Clutch Operation
220
General Operation
220
Driven Clutch Operation
221
Pvt Break-In (Drive Belt / Clutches)
221
Maintenance / Inspection
222
Overheating / Diagnosis
223
Pvt System Service
224
Disassembly
224
Assembly
225
Drive Belt
227
Belt Removal
227
Belt Installation
227
Belt Inspection
228
Pvt Break-In (Drive Belt / Clutches)
228
Clutch Alignment
229
Clutch Alignment Tool Use
229
Setting Center-To-Center Distance
230
Drive Clutch Service (4X4 - Non Ebs)
231
Exploded View (Non Ebs)
231
Clutch Disassembly
231
Shift Weight Inspection
233
Spider Removal
233
Button to Tower Clearance Inspection
235
Bearing Inspection
235
Clutch Inspection
236
Moveable Sheave Bushing Inspection
237
Clutch Assembly
237
Ebs Drive Clutch Service (6X6)
239
Ebs Drive Clutch Exploded View (6X6)
239
Drive Clutch Disassembly
239
Shift Weight Inspection
241
Spider Removal
241
Button to Tower Clearance Inspection
243
Drive Clutch Inspection
243
Moveable Sheave Bushing Inspection
244
One-Way Clutch Inspection (Ebs Drive Clutch)
245
Drive Clutch Reassembly
245
Drive Clutch Bushing Service (Non Ebs and Ebs)
247
Bushing Service
247
Driven Clutch Service (Non Ebs)
250
Exploded View (Non Ebs)
250
Clutch Disassembly / Inspection
250
Clutch Assembly
253
Driven Clutch Service (Ebs)
254
Driven Clutch Exploded Views (Ebs)
254
Clutch Disassembly
255
Clutch Assembly
258
Driven Clutch Bushing Service
262
Driven Clutch Bushing Service (Non Ebs and Ebs)
262
Troubleshooting
264
Chapter 7 Final Drive
267
Gearcase Fluid / Capacity
269
Specifications
269
Torque Table
269
Front Hub
271
Disassembly
271
Assembly
271
Front Gearcase Removal and Installation (Adc and Non Adc)
272
Gearcase Removal
272
Gearcase Installation
273
Front Gearcase - Centralized Hilliard Non Adc (4X4)
274
Operation Non Adc
276
Disassembly / Inspection Non Adc
277
Reassembly / Inspection Non Adc
281
Front Gearcase Diagnosis
284
Setting Ring Gear Backlash Non Adc
285
Front Gearcase - Centralized Hilliard Adc (6X6)
287
Operation
287
Adc Gearcase Exploded View
288
Adc Operation
290
Front Gearcase Diagnosis
291
Coil Testing
292
Adc Differential Hydraulic Circuit Bleeding
293
Disassembly / Inspection
293
Adc Gearcase Piston Replacement Procedure
298
Assembly
301
Setting Ring Gear Backlash
304
Middle Gearcase (6X6)
306
Removal
306
Disassembly and Inspection
306
Reassembly
310
Installation
312
Middle Gearcase Exploded View
313
Front Drive (CV) Shaft
314
Inspection
314
Removal
314
Installation
316
Rear Hub
317
Removal
317
Disassembly
318
Assembly
319
Installation
320
Rear Drive (CV) Shaft
321
Inspection
321
Removal
321
Installation
322
Rear Gearcase (6X6)
323
Removal
323
Disassembly and Inspection
323
Reassembly
325
Installation
326
Rear Gearcase Exploded View (6X6)
327
CV Drive Shaft Service
328
Drive Shafts and Propshafts Components
328
Drive Shaft and CV Joint Handling Tips
329
Outer CV Joint / Boot Replacement
332
Inner Plunging Joint / Boot Replacement
334
Drive Shaft Exploded Views
337
Prop Shaft - Front or Rear
338
Removal and Installation
338
U-Joint Service
339
Disassembly
339
Assembly
340
Chapter 8 Transmission
341
General Information
342
Lubrication
342
Torque Specifications (4X4)
342
Transmission Service (4X4)
343
Transmission Frame Mounts
343
Transmission Upper Frame Mount
344
Transmission Rear Stabilizer Mounts
345
Transmission Control Arm Bracket Mounts
346
Shift Linkage Inspection
346
Gear Selector Removal
346
Transmission Removal
347
Transmission Installation
347
Troubleshooting Checklist
348
Transmission Disassembly
349
Snorkel / Output Gear Backlash Procedure
355
Transmission Assembly
357
Torque Specifications
364
Lubricant / Capacity
364
Transmission Removal
365
Disassembly
366
Assembly
373
Transmission Installation (6X6)
378
Troubleshooting
379
Transmission Exploded View (4X4)
380
Sportsman Transmission Exploded View (4X4)
380
Transmission Exploded View (6X6)
382
Sportsman Transmission Exploded View (6X6)
382
Chapter 9 Brakes
385
Component Service Limits
387
Special Tools
387
Specifications
387
Torque Table
387
Brake System Exploded View (4X4)
388
Brake System Exploded View
388
Brake System Exploded View (6X6)
389
Brake System Exploded View
389
Brake Caliper Explioded Views
390
Front Brake Caliper Assembly
390
Rear Brake Caliper Assembly
391
Hydraulic Brake System
392
Operation Overview
392
Brake Noise Troubleshooting
393
Brake Bleeding / Fluid Change
393
Front Master Cylinder
396
Removal
396
Installation
396
Front Brake Pads
397
Pad Removal
397
Assembly
398
Brake Burnishing Procedure
399
Front Brake Disc
400
Inspection
400
Removal / Replacement
401
Front Caliper
402
Removal
402
Inspection
403
Reassembly
403
Installation
404
Rear Brake Pad
405
Rear Pad Removal
405
Rear Pad Installation
406
Brake Burnishing Procedure
407
Rear Caliper
408
Removal and Inspection
408
Assembly
409
Rear Brake Disc
411
Inspection
411
Rear Master Cylinder
412
Overview
412
Rear Master Cylinder Removal / Installation
413
Chapter 10 Electrical
415
General Information
418
Instrument Cluster
419
Overview
419
Instrument Cluster Diagnostic Mode
421
Setting a New Service Interval
424
Efi Diagnostic Mode
425
Speedometer Removal
428
Speedometer Installation
429
Speedometer Troubleshooting
430
Test 1 - no All Wheel Drive
430
Test 2 - no Display / Test 3 - no Reverse Speed Limit
431
Test 4 - no Awd Hub Safety Limiter
432
Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
433
Test 6 (4X4) - Vehicle Speed Sensor
434
Speed Sensor Location 4X4
434
Speed Sensor Testing
434
Test 7 - no Fuel Gauge / Test 8 - Transmission Switch
435
All Wheel Drive (Awd) Coil (4X4)
436
Operation Overview
436
Diagnosing System Failures
436
Active Descent Control (Adc) Coil (6X6)
437
Operation Overview
437
Diagnosing System Failures
437
Cooling System Components
438
Fan Control Circuit Operation / Testing
438
Fan Control Circuit Bypass Test
438
Coolant Temperature Sensor
438
Fan Motor Current Draw
439
Gear Position Indicator Switch
440
Test Diagram
440
Throttle Release System (Trs) Switch
441
Trs Switch Operation
441
Trs Operation Test
441
Charging System
442
Current Draw - Key off
442
Charging System "Break Even" Test
442
Alternator Output Test
443
Charging System Testing Flow Chart
444
Relays
445
Operation
445
Fuses/Circuit Breaker
446
Operation
446
High Beam Headlight Bulb Replacement
447
Headlight Housing Replacement
448
High Beam Headlight Adjustment
449
Lower Headlamp Removal / Installation
449
Low Beam Headlight Adjustment
450
Headlamp Switch Test
450
Brake Light Replacement (4X4)
451
Brake Light Switch (4X4)
452
Brake Light Switch (6X6)
452
Brake Lamp/Tail Lamp Replacement (6X6)
453
Fuel Sender
454
Testing
454
Accessory Power
455
Wire Connections
455
Starter System
456
Starter Lockout Overview and Diagnostic
456
Troubleshooting
457
Voltage Drop Test
458
Starter Solenoid Bench Test
458
Starter Motor Removal
458
Starter Installation
459
Starter Drive
459
Starter Exploded View
460
Starter System Testing Flow Chart
461
Flow Chart
461
Battery
462
Battery Identification
462
Battery Conductance Analyzer
462
Battery Activation (Conventional)
463
Battery Terminals/Bolts
463
Conventional Battery Inspection / Removal
464
Conventional Battery Installation
465
Conventional Battery Testing
465
Conventional Battery Ocv - Open Circuit Voltage Test
465
Conventional Battery Specific Gravity Test
465
Battery Load Test
466
Off Season Storage
466
Charging Procedure
467
Low Maintenance Battery
467
Low Maintenance Battery Charging
468
Low Maintenance Battery Inspection / Removal
469
Low Maintenance Battery Installation
469
Low Maintenance Battery - Ocv- Open Circuit Voltage Test
469
Low Maintenance Battery Load Test
470
Low Maintenance Battery Charging Procedure
470
Low Maintenance Battery Off-Season Storage
471
Troubleshooting Diagrams
472
Overview
472
All Wheel Drive - Efi
472
Charging Circuit - Efi
472
Cooling Fan - Efi
473
Fuel Pump - Efi
473
Gear Switch - Efi
474
Power Circuit - Efi
474
Reverse Override - Efi
475
Fan Control - Efi
475
Start Circuit - Efi
476
Start Enable - Efi
476
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