Overheating / Diagnosis - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

Overheating / Diagnosis

During routine maintenance, or whenever PVT system overheating is evident, it's important to check the inlet and
outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system
operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended
low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
POSSIBLE CAUSES
Loading the vehicle into a truck or tall
trailer when in high range.
Starting out going up a steep incline
from a stopped position.
Driving at low RPM or low ground speed
(at approximately 3-7 MPH).
Insufficient warm-up of vehicles
exposed to low ambient temperatures.
Slow and easy clutch engagement.
Towing/Pushing at low RPM/low ground
speed.
Plowing snow, dirt, etc./utility use.
Stuck in mud or snow.
Climbing over large objects from a
stopped position.
Belt slippage from water or snow
ingestion into the PVT system.
Clutch malfunction.
Poor engine performance.
GENERAL RANGE OPERATION
GUIDELINES:
Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning.
SOLUTIONS / WHAT TO DO
Shift transmission to Low during loading of the vehicle to prevent belt
burning.
When starting out on an incline, use Low, or dismount the vehicle after first
applying the park brake and perform the "K" turn.
Drive at higher speed or use Low. The use of Low is highly recommended
for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
become more flexible and prevent belt burning.
Fast, effective use of the throttle for efficient engagement.
Use Low only.
Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
application to engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
application to engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm
from idle to full throttle. Repeat several times as required. During this
procedure, the throttle should not be held at the full position for more than
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
burning.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact
you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
through rough terrain (swamps, mountains, ect.), low ground speeds.
High: High ground speeds, speeds above 7 MPH.
CAUTION
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
CLUTCHING
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