Auxiliary Brake Adjustment; Suspension: Spring Preload Adjustment; Front Suspension; Rear Suspension - Polaris 2008 sportsman 800efi Service Manual

2. While turning the rear wheels by hand, apply the auxiliary
foot brake. This brake should not stop the wheels from
turning until the lever is half way between its rest position
and bottoming on the footrest.
Auxiliary Foot Brake
Pedal - Full Height
Floor Board Surface

Auxiliary Brake Adjustment

Use the following procedure to inspect the hydraulic auxiliary
(foot) brake system and adjust or bleed if necessary:
First, check foot brake effectiveness by applying 50 lb. (approx.)
downward force on the pedal. The top of the pedal should be at
least 1 inch, (25.4mm) above the surface of the footrest.
1/8 to 1/4 inch
Free Play
If less than one inch, two things must be examined:
Free Play:
Foot Brake Freeplay:
1/8 - 1/4 inch (3.2 - 6.35 mm)
If free play is excessive, inspect pedal, linkage, and master
cylinder for wear or damage and replace any parts as needed.
Full Engagement
1 inch or greater
Floorboard
= In. / mm.
Bleeding:
If free play is correct and brake pedal travel is still excessive, air
may be trapped somewhere in the system. Bleed the hydraulic
auxiliary brake system in a conventional manner, following the
procedure outlined in Brake Chapter 9.

Suspension: Spring Preload Adjustment

Operator weight and vehicle loading affect suspension spring
preload requirements. Adjust as necessary. Use Shock Spanner
Wrench (PN 2870872) to adjust the rear springs.

Front Suspension

• Compress and release front suspension. Dampening
should be smooth throughout the range of travel.
• Check all front suspension components for wear or
damage.
• Inspect front strut cartridges for leakage.

Rear Suspension

• Compress and release rear suspension. Dampening
should be smooth throughout the range of travel.
• Check all rear suspension components for wear or
damage.
• Inspect shock for leakage.

CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the ATV for
damage, tears, wear, or leaking grease. If the rubber boot
exhibits any of these symptoms, replace the boot. Refer to
Chapter 7 for CV boot replacement, or have your Polaris dealer
replace the boot.
INSPECT BOOTS
MAINTENANCE
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