Polaris Sportsman 800 EFI Big Boss 6x6 2012 Manuals

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Polaris Sportsman 800 EFI Big Boss 6x6 2012 Service Manual

Polaris Sportsman 800 EFI Big Boss 6x6 2012 Service Manual (485 pages)

6X6

Brand: Polaris | Category: Offroad Vehicle | Size: 55.23 MB

Table of Contents

Chapter 1 1 General Information

7
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
- 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
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  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
Chapter 5 Body / Steering / Suspension

183
- General Information
  184
- Multi-Function Pliers
  184
- Torque Specifications
  184
- Decal Replacement
  185
- Body
  186
- 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
- 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
- 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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