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Manuals and User Guides for Polaris Sportsman 800 EFI. We have 7 Polaris Sportsman 800 EFI manuals available for free PDF download: Service Manual, Owner’s Manual, Owner’s Manual For Maintenance And Safety

• 232, Polaris Sportsman 800 EFI 4×4 2012 6.16 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 3. Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon coating. Wear is determined by the amount of Teflon remaining on the bushing. Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 4. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace …

• 158, 4.24 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. CRANKSHAFT POSITION SENSOR (CPS) Operation Overview The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft. A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel. The inductive speed sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away fr…

• 265, 6 6.49 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Troubleshooting, Continued….. SITUATION PROBABLE CAUSE REMEDY PVT cover overheating (melting) -Plugged air intake or outlet. -Belt slippage due to water, oil, grease, etc., rubbing on cover. -Clutches or weight being applied to cover while in operation. -High vs. low range. -Clear obstruction -Inspect system. Clean, repair or replace as necessary. Seal PVT system ducts. -Remove weight. Inf…

• 412, 9.28 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. REAR MASTER CYLINDER Overview Polaris disc brake systems are light weight, low maintenance and perform well in the conditions ATVs routinely encounter. However, there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. • Perform a brake burni…

• 443, 10 10.29 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Alternator Output Test Three tests can be performed using a multimeter to determine the condition of the stator (alternator). TEST 1: Resistance Value of Each Stator Leg 1. Measure the resistance value of each of the three stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should measure 0.22 Ω ± 15%. TEST CONNECT METER WIRES TO: READING IN OHMS Charge Coil Y1 to Y2 0.22…

• 442, 10.28 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. CHARGING SYSTEM Current Draw — Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as…

• 19, 1.13 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Standard Bolt Torque Specification BOLT SIZE GRADE 2 FT. LBS. (NM) GRADE 5 FT. LBS. (NM) GRADE 8 FT. LBS. (NM) 1/4-20 5 (7) 8 (11) 12 (16) 1/4-28 6 (8) 10 (14) 14 (19) 5/16-18 11 (15) 17 (23) 25 (35) 5/16-24 12 (16) 19 (26) 29 (40) 3/8-16 20 (27) 30 (40) 45 (62) 3/8-24 23 (32) 35 (48) 50 (69) 7/16-14 30 (40) 50 (69) 70 (97) 7/16-20 35 (48)…

• 105, Polaris Sportsman 800 EFI 4×4 2012 3 3.45 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 15. Discard original springs and install the new springs into the grooves of the cam gear. 16. Insert the pointed dowels from the Tapered Pins (PU- 45497-1) into the cam gear. To Assemble: * Hold the spring with one finger. * Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with th…

• 116, 3.56 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 14. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods. 15. Install the piston pin circlips (F). The circlip ends should be installed at the 12 O’clock position. IMPORTANT: While installing in piston pins, cover all engine passages. The clip could fall into the engine durin…

• 260, 6.44 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 9. Install the spider dampener (G) inside the outer spider and install the inside spider plate (H). 10. Install the spider assembly onto the shaft with the retaining ring on top of the spider. NOTE: Use the marks previously made to align the skip tooth spider, or use the “X” on top of the spider and align it with the skip tooth on the shaft. 11. Place the clutch into the Universa…

• 289, 7 7.23 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. REF. # DESCRIPTION QTY REF. # DESCRIPTION QTY 1 O-ring 2 17 Roll Cage Assembly 1 2 1/4″ Tubing 1 18 8-32 x 3/8″ Screws 4 3 1/4-20 Screws 5 19 Spacer, Gear 1 4 Armature Plate 1 20 Pump Assembly 1 5 Bushing 1 21 Wire Connector 1 6 Vent 1 22 O-ring, Pump 2 7 Cap, Bleed Screw 2 23 Seals 3 8 Output Hub Sub-Assembly 1 24 Bleeder Valve 2 9 Cover Assembly 1 25 Cam Assembly 1 10…

• 395, 9 9.11 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 14. Torque the screw to specification . Master Cylinder Cover Screw: 7 in-lbs (0.79 Nm) 15. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2”, (1.3 cm) from handlebar. 16. Check brake system for fluid leaks and inspect all …

• 469, 10 10.55 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Low Maintenance Battery Inspection / Removal The battery is located on the rear, left-side of the frame. 1. Remove the seat and Disconnect holder strap. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. CAUTION Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstall the negative cable las…

• 167, 4 4.33 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. DIGITAL WRENCH® OPERATION Digital Wrench® Diagnostic Software Overview NOTE: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: • View or clear trouble cod…

• 339, 7 7.73 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. U-JOINT SERVICE Disassembly WARNING Always wear eye protection when working with spring- tensioned components 1. Remove internal or external snap ring from all bearing caps. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting (if equipped) and mark inner and outer yoke for correct re-positioning during installation. 2. Support inner yoke as shown and drive…

• 109, Polaris Sportsman 800 EFI 4×4 2012 3 3.49 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 31. Carefully press the gear off the assembly while supporting the housing assembly. CAUTION Wear appropriate safety gear during this procedure. Protective gloves, clothing and eyewear are required. 32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly. 33. Place the shaft in a press to remove the…

• 340, 7.74 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Assembly 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in. 2. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cros…

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wide family of Polaris owners. We proudly produce an exciting line of 
utility and recreational products. 
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Always follow the instructions and recommendations in this manual. 
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and 
should be performed only by a Factory Certified Master Service Dealer 
(MSD) Technician. Please see your dealer for all of your service needs 
during (and after) the warranty period.

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www.polarisindustries.com.