General Information - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

GENERAL INFORMATION

WARNING
* Gasoline is extremely flammable and explosive under
certain conditions.
* EFI components are under high pressure. Verify
system pressure has been relieved before disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result.
* Do not overfill the tank. The tank is at full capacity
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are poisonous
and can cause loss of consciousness and death in a
short time.
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
* If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
* Always stop the engine and refuel outdoors or in a
well ventilated area.
Special Tools
PART NUMBER TOOL DESCRIPTION
Polaris EFI Diagnostic
Software
PU-47063-A
(Digital Wrench)
Fuel Pressure
PU-43506-A
Test Kit
Fuel Pressure
PU-48838
Test Valve Kit
Throttle Position Sensor
2201519-A
Tester Harness
Digital Wrench®
PU-47471
SmartLink Kit
Bosch Automotive Service Solutions: 1-800-345-2233 or
polaris.service-solutions.com .
NOTE: The EFI fuel system remains under high
pressure, even when the engine is not running.
Before attempting to service any part of the fuel
system, the pressure must be relieved.
The Sportsman utilizes different-style quick-connect
fuel line dampers where Special Tool PU-48838 is to
be connected and used with Tester PU-43506-A.
Fuel Pressure Test Valve - PU-48838
Polaris EFI Diagnostic Software (Digital Wrench®) -
PU-47063-A
This dealer-only software installs on laptop computers
equipped with a CD drive and serial port connection, and
is designed to replace multiple shop tools often used to
test EFI components. It also includes step-by-step
diagnostic procedures to aid technician repair and
troubleshooting.
Throttle Position Sensor Tester Harness - 2201519-A
This harness allows the use of a digital multi-meter to
test
procedures. Replaces PU-47082. (DO NOT order
Digital Wrench® SmartLink Unit Kit - PU-47471
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
FUEL SYSTEM - GENERAL
TPS function as well perform
4
initialization
4.3