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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

• 268, 7.2 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . .7.55 REMOVAL . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . .…

• 406, Polaris Sportsman 800 EFI 4×4 2012 9.22 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 8. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Rear Brake Pad Thickness Service Limit: .180” (4.6 mm) Rear Pad Installation 1. Install new brake pads in caliper body. WARNING If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use only new clean …

• 407, 9 9.23 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 3. Install caliper and torque the mounting bolts to specification. Caliper Mount Bolt: 18 ft-lbs (24 Nm) 4. Install the slide bolt snap ring. Torque the slide pin to specification. Caliper Slide Bolt: 30-35 ft-lbs (41-48 Nm) 5. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to …

• 410, 9.26 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 3. Install brake pads in caliper body with friction material facing each other. Install the slide pins and the slide pin retaining rings. Torque the slide pins to specification. NOTE: The slide pins should be torqued when installed on caliper mount. Slide Pin Torque: 30-35 ft-lbs (41-48 Nm) 4. Install caliper and torque mounti…

• 177, 4 4.43 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. TROUBLESHOOTING Diagnostics Using “Blink Codes” To enable the blink codes, turn the ignition from “OFF” to “ON” 3 times, leaving it ‘on’ the 3rd time, within 5 seconds. Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, on the instrument cluster LCD. The word ‘END’ will display after all codes have been transmitted…

• 224, 6.8 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. PVT SYSTEM SERVICE Disassembly Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove the LH storage box to gain access to PVT outer cover (see Chapter 5 for removal). 3. Remove PVT air outlet duct hose. 4. Remove outer PVT cover screws. 5. Mark the drive belt direction of rotation and remove drive belt. See “…

• 279, 7 7.13 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 11. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Inspect the H-springs, but do not remove them from the roll cage. 12. Inspect the armature plate for a consistent wear pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation. NOTE: See “FRONT GEARCASE DIAGNOSIS” later in this chapter for more details…

• 117, 3 3.57 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 16. Install camshaft thrust plate (G) with new bolts. Torque bolts to specification. NOTE: New bolts have patch lock on the threads and do not require Loctite® Thrust Plate Screw: 115 ± 12 in-lbs (13 ± 1.35 Nm) 17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors. 18. Ap…

• 388, 9.4 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. BRAKE SYSTEM EXPLODED VIEW (4X4) Brake System Exploded View BRAKES
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• 315, 7 7.49 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 8. Remove hub nut and hub assembly. 9. Remove cotter pin and nut from lower A-arm ball joint. 10. Remove lower A-arm from ball joint using a ball joint fork tool. 11. Pull strut assembly out while pivoting the CV drive shaft away until it clears the strut assembly. 12. Pull outward sharply on CV shaft assembly to remov…

• 191, Polaris Sportsman 800 EFI 4×4 2012 5 5.9 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Front Rack / Storage Box Lid Assembly (4×4 and 6×6) BODY / STEERING / SUSPENSION
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• 283, 7 7.17 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 12. Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cut-grooves of the ring gear. NOTE: Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves. 13. Install the output hub and cover plate assembly with a new o-ring (arrow) onto the gearcase. NOTE: Verify the square O-ring (arrow) is …

• 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 beari…

• 429, 10 10.15 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Speedometer Installation 1. Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the pod assembly more easily. 2. Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway. 3. Hold the pod assembly securely and insert the instrument cl…

• 373, 8 8.33 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. Assembly 1. Reinstall the chain onto the front output shaft and rear output shaft. 2. Install front and rear output shafts into the case. 3. Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply Crankcase Sealant (PN 2871557) to the mating surfaces. 4. Reinstall the t…

• 254, 6.38 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. DRIVEN CLUTCH SERVICE (EBS) Driven Clutch Exploded Views (EBS) CLUTCHING
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• 242, Polaris Sportsman 800 EFI 4×4 2012 6.26 9924864 — 2012-2014 SPORTSMAN 800 / 6X6 © Copyright 2013 Polaris Sales Inc. 2. Inspect the Teflon coating on the moveable sheave bushing. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon® is visible on the bushing. Refer to bushing replacement in this chapter. 3. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with …