Polaris Sportsman 800 Big Boss Owner'S Manual Download Page 1

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Owner's Manual

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Pantone 426 C

for Maintenance and Safety

Sportsman

Big Boss 6X6

Summary of Contents for Sportsman 800 Big Boss

Page 1: ...Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Pantone 426 C for Maintenance and Safety Sportsman Big Boss 6X6 ...

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...te this vehicle on HILLS steeper than 25 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS S Use an approved HELMET AND PROTECTIVE GEAR S Avoid paved surfaces Pavement may seriously affect handling and control S Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns S Use OVERRIDE for reverse speed limiter with caution To...

Page 5: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your Polaris dealer knows your vehicle best and is i...

Page 6: ... quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is ex...

Page 7: ...afety 7 Features and Controls 26 Operation 46 Emission Control Systems 66 Maintenance 67 Adjustments 116 Troubleshooting 118 Specifications 122 Polaris Products 124 Declaration of Conformity 125 Warranty 126 Maintenance Log 134 Index 137 ...

Page 8: ...al injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 9: ...riving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating this vehicle Keep this manual with the vehicle Never operate this vehicle without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of ag...

Page 10: ...k using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number _____________________________________________...

Page 11: ...iderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training This Polaris vehicle is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area W...

Page 12: ...exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on th...

Page 13: ...tect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris vehi cle any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris vehicle is terminated if any equipm...

Page 14: ...different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the vehicle unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Opera...

Page 15: ...ge clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operati...

Page 16: ...rly and eye protection goggles or face shield Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating this vehicle Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the vehicle which may re...

Page 17: ... turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate the vehicle on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate this type of vehicle on public streets roads and highways Operating at Excessive Speeds Operating the vehicle at ex...

Page 18: ...ion loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or ot...

Page 19: ...ays check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing t...

Page 20: ... Dismount on uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in the owner s manual See page 58 If the vehicle begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the service brake gradually When fully stopped apply the rear brak...

Page 21: ...terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that co...

Page 22: ...er obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 60 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexp...

Page 23: ... Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 61 Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Poor Visibility Operating the vehicle in darkness or inclement weather could result in a collision or a...

Page 24: ... your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Operating on Frozen Bodies of Water Operating on frozen bodies ...

Page 25: ...cal disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry g...

Page 26: ...sk of losing control USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 25 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS Use an approved HELMET AND PROTECTIVE GEAR Avoid paved surfaces Pavement may seriously affect handling and control Use proper ...

Page 27: ...51 Front Rack Box Warning WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads 100 lbs 45 kg 7175662 Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply thro...

Page 28: ...g WARNING Remove flammable containers from box before refueling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers Maximum Box Load 800 lbs 363 kg 7079316 Clutch Cover Warning Age 16 Warning Container No Passenger Warning ...

Page 29: ...WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX V...

Page 30: ...le is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on This switch is also used to toggle through the modes of the rider information center See page 37 All Wheel Drive AWD Switch See page 34 for AWD information Mode Reverse O...

Page 31: ...ine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 51 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to op...

Page 32: ...tronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine speed and vehicle move ment are controlled by pressing the throttle lever The thrott...

Page 33: ...ss of control which may result in serious injury or death Operating the vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate the vehicle with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle The braking system is controlled by the two brake levers located on the handlebars The service brake left ...

Page 34: ...Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Auxiliary Brake Lever Squeeze the auxiliary brake lever right lever toward the handlebar to apply the middle axle rear brake only Use the auxiliary brakes for addi tional braking or for backup if the service brake system f...

Page 35: ... of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion The master cylinders are located on the left and right handlebars Check the fluid levels of both master cylinders before each use of the vehicle 1 Position the vehicle on a level surface 2 Position the handlebars so the master cylinders are level 3 View the brake fluid level ...

Page 36: ...d position WARNING Operating the vehicle while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill Another option i...

Page 37: ... the transmission in park and lock the parking brake when ever the vehicle is left unattended Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than 7 mph 11 km h for extended periods of time Fuel Tank Cap Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add ...

Page 38: ...hen the switch is on 4X4 the vehicle is in all wheel drive and the AWD indicator light in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The override sw...

Page 39: ...If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gea...

Page 40: ...f the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC ...

Page 41: ... that limits the vehicle s speed to approximately 7 9 mph 11 14 km h Refer to page 26 for additional information NOTICE High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument clust...

Page 42: ...ode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments...

Page 43: ...les traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in o...

Page 44: ...and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnosti...

Page 45: ... for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds eac...

Page 46: ...e button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 If you scroll past the intended number press and hold the button until the hours cycle back to zero 6 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The ...

Page 47: ...tions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in park 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END...

Page 48: ...ump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery volt...

Page 49: ...46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circ...

Page 50: ...hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage ...

Page 51: ...ry the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and be...

Page 52: ... pressure 87 Wheels fasteners Inspect ensure fastener tightness 87 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 33 72 Coolant level if applicable Ensure proper level 82 83 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 28 117 Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 27 Air fi...

Page 53: ...ibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests 9 Never consume alcohol or drugs b...

Page 54: ...hicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to onc...

Page 55: ... to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the vehicle is used year round che...

Page 56: ...on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 57: ...teer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turn...

Page 58: ... traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handl...

Page 59: ...See page 36 2 Drive straight uphill 3 Avoid steep hills 25 maximum 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill 8 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the vehicle to flip over backwards 9 Remain al...

Page 60: ...ossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Shift body weight uphill 4 Keep your feet on the footrests 5 If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ...

Page 61: ...ending or descending a hill See page 36 2 Avoid steep hills 25 maximum 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol ...

Page 62: ...the vehicle or on the left if the vehi cle is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake and remount the vehicle from the uphill side keeping body wei...

Page 63: ...ar gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 98 then see your dealer for serv...

Page 64: ...ting in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees ...

Page 65: ... 6 Never open the throttle suddenly 7 Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in ...

Page 66: ...and forward in the cargo box as possible Always attach the tow load to the hitch point designated for your vehicle Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Do not block the front headlight beam when carrying loads on the front rack Do not tow any trailer on a grade steeper than 15 Vehicle should never exceed 10 mph...

Page 67: ...Balance handling and control may be affected 4 Slow down 5 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured 6 Always attach a towed load to the hitch point NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious dam...

Page 68: ...the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box Never carry passengers in the cargo box 5 Pull the cargo box release lever forward 6 Lift the front of the cargo box to dump the cargo 7 Lower the cargo box Make sure the latch is secure before operating WARNING Operating with the cargo box in the raised position can cause serious injury ...

Page 69: ... an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in park 3 Lock the parking brake 4 Always block the rear wheels on the downhill side ...

Page 70: ...ubject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An ele...

Page 71: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high R...

Page 72: ...tenance interval is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Q Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 48 X Front suspension Pre Ride X Rear suspension Pre Ride Tires Pre Ride X Brake fluid level Pre Ride X Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X ...

Page 73: ...level change yearly X Transmission oil 25 H Monthly 155 250 Inspect level change yearly X E Engine breather filter if equipped 25 H Monthly 155 250 Inspect clean if needed X General lubrication 50 H 3 M 310 500 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 310 500 Inspect lubricate adjust Q Steering 50 H 6 M 310 500 Lubricate X Front suspension 50 H 6 M 310 500 Lubricate X Rear s...

Page 74: ... Engine mounts 100 H 12 M 620 1000 Inspect Exhaust muffler pipe 100 H 12 M 620 1000 Inspect Q E Spark plug 100 H 12 M 620 1000 Inspect replace as needed X Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 620 1000 Inspect clean replace worn parts Q Shift selector lubricant 200 H 24 M ...

Page 75: ...ance Synthetic 2W 50 See page 72 Brake Fluid DOT 4 Only See page 31 Drive Chains O ring chain lube or SAE 80 90 Lubricate as often as required before each ride in wet condi tions Gear Selector Oil PS 4 PLUS Performance Synthetic 2W 50 Maintain oil level at the center of the shift rail Do not overfill Transmission Oil Polaris Premium Synthetic Gearcase Lube See page 75 Front Gearcase Demand Drive O...

Page 76: ...il Level Access the oil dipstick and fill tube from the left side of the vehicle 1 Position the vehicle on a level surface 2 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick com pletely but do not lock it The dipstick must be inserted com pletely to keep the angle and depth of the stick consistent 4 Remove the dipstick and check the oil level Maint...

Page 77: ...the crankcase 5 Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 6 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 20 ft lbs 27 Nm 8 Place shop towels beneath the oil filter Usin...

Page 78: ...e filter gasket contacts the sealing surface then turn it an additional 1 2 turn 12 Remove the dipstick 13 Add two quarts 1 9 l of recommended oil 14 Place the transmission in park 15 Lock the parking brake 16 Start the engine Allow it to idle for one to two minutes 17 Stop the engine 18 Check for leaks 19 Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick 2...

Page 79: ...from the right side of the vehicle Access the drain plug from the left side of the vehicle Oil Check 1 Position the vehicle on a level surface 2 Remove the footwell see page 86 3 Remove the fill plug Check the oil level 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 5 Reinstall the footwell Oil Change 1 Remove the footwell see page 86 2 Place a drain pan under the gearcase Remove the drain pl...

Page 80: ...aintain the fluid level at the bottom of the fill hole threads See below for capacity The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hol...

Page 81: ...fill plug 2 Place a drain pan under the demand drive unit 3 Remove the drain plug Allow the fluid to drain completely 4 Clean and reinstall the drain plug Torque to 11 ft lbs 15 Nm 5 Add the recommended fluid 6 Reinstall the fill plug Torque to 8 10 ft lbs 11 14 Nm 7 Check for leaks 8 Dispose of used fluid properly ...

Page 82: ...s prod ucts Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil...

Page 83: ...il level even with the bottom thread of the fill plug hole Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Remove the fill plug 2 Remove the drain plug from the bottom of the gearcase Drain the oil into a drain pan Discard used oil properly 3 Clean and...

Page 84: ... Maintain the fluid level between the minimum and maximum marks on the reservoir We recommend the use of Polaris Demand Drive Plus Fluid See page 124 for the part numbers of Polaris products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system 1 Open the front box cover and pull open the access door 2 View the fluid level in the reservoir 3 If the level i...

Page 85: ...d 5 Remove the protective caps from the bleeder valves 6 Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will ...

Page 86: ...e system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 124 ...

Page 87: ...he radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover and pull open the access door 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standa...

Page 88: ...l WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 31...

Page 89: ...d position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement o...

Page 90: ...e side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securin...

Page 91: ...ecom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine 2 Place the transmission in park 3 Lock the parking brake 4 Loo...

Page 92: ...vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 90 ft lbs ...

Page 93: ...c type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat Main Filter Pre Filter ...

Page 94: ... fuses are provided in a com partment on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the access door 4 Secure the box cover Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A Main Fuse Ignition Lighting 20A Accessories 12...

Page 95: ...e of the lamp 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 5 Unplug the headlamp from the...

Page 96: ...he floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight po...

Page 97: ...ghts Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw Phillips Screw ...

Page 98: ...ring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the e...

Page 99: ...all the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly 2 Remove the lamp 3 Apply dielectric grease to the socket and install the new lamp 4 Test the light for proper operation 5 Reinstall t...

Page 100: ...n after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 97 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate...

Page 101: ...gine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non...

Page 102: ... to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 7 Take the vehicle to your dealer for service as so...

Page 103: ...emove the arrestor clean out plug from the bottom of the muffler Be sure to clean out both arrestors if your model has two 2 Place the transmission in park 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe wit...

Page 104: ...loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manu...

Page 105: ...e system s depen dence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to pro...

Page 106: ...park 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible Co...

Page 107: ...duce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery ...

Page 108: ...nect the black negative battery cable first 5 Disconnect the red positive battery cable last 6 Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle ...

Page 109: ...uctions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals ...

Page 110: ...tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 124 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the ba...

Page 111: ... sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop ch...

Page 112: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At l...

Page 113: ...s to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not ...

Page 114: ...r washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your...

Page 115: ... Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the produ...

Page 116: ... Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and F...

Page 117: ...veral minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of Premium 4 Syn thetic 0W40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of each spar...

Page 118: ...le with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all m...

Page 119: ...e the transmission in park 3 Lock the parking brake 4 Secure the fuel cap oil cap and seat 5 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting ...

Page 120: ...orrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact ...

Page 121: ...the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot a...

Page 122: ... Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of contro...

Page 123: ... Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug ga...

Page 124: ...inked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kin...

Page 125: ...ections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your d...

Page 126: ...bs 680 4 kg Unbraked Trailer Towing Capacity 2127 lbs 965 kg Overall Length 112 in 284 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 79 5 in 202 cm Ground Clearance 10 5 in 27 cm Dry Weight 1060 lbs 481 kg Minimum Turning Radius 152 in 386 cm unloaded Engine EH076OLE020 Displacement 760 cc Bore x Stroke 80 x 76 Alternator Output 500 Watts 3000 rpm Compression Ratio 10 1 Start...

Page 127: ... kPa Tires Pressure Rear 25x11 12 10 psi 68 9 kPa Brakes Front Hydraulic Disc Brakes Rear Hydraulic Disc Brakes Auxiliary Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Mete...

Page 128: ...237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint ...

Page 129: ...2009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH27__ SPORTSMAN 300 2008 2009 2010 81 1 ___LH46__ SPORTSMAN 400 2008 2009 2010 80 2 ___MN50__ SPORTSMAN 500 EFI 2008 2009 2010 80 4 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009 2010 80 8 ___TN55__ ___DN...

Page 130: ...Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signe...

Page 131: ... parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effectiv...

Page 132: ...y abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FO...

Page 133: ... original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above t...

Page 134: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 135: ...is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For q...

Page 136: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followin...

Page 137: ...due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for perform...

Page 138: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 139: ...135 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 140: ...136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 141: ...eel Care 111 Cleaning and Storage 109 114 C Clothing 9 Clutching 123 Codes 43 45 Cold Weather Operation 51 Consumer Product Safety 7 Coolant Bottle 82 Coolant Radiator 83 Cooling System 82 83 Corrosion Removal Chrome 111 Crankcase Emission Control System 66 D Demand Drive Capacities 76 Demand Drive Fluid 76 77 Disengage Active Descent Control 36 Downloading Codes 43 45 Drive Belt Wear Burn 118 Dri...

Page 142: ...t Cluster 37 45 K Key Switch 27 K Turn 58 L Lights 91 95 Headlight Housing 94 Headlight Lamp Upper 91 High Beam Adjustment 92 Low Beam Adjustment 93 Lower Headlamp Replacement 95 Taillight Brakelight 95 Low Beam Adjustment 93 Low Range Use 102 Lower Headlamp Replacement 95 Lubrication Recommendations 71 M Maintenance Chart 67 70 Master Cylinder 31 Middle Gearcase Oil Check 79 Middle Gearcase Oil C...

Page 143: ...g Recommendations 96 Spark Plug Torque Specification 96 Spark Plugs 96 97 Specifications 123 Spring Adjustment Rear Shock 116 Starting the Engine 51 Steering Assembly 86 Storage 109 114 Storage Tips 112 114 S Switches AWD Switch 26 34 Engine Stop Switch 27 Headlight Switch 27 Main Key Switch 27 Mode Switch 26 Reverse Override Switch 26 Stop Switch 27 T Taillight 95 Throttle Body Adjustment 117 Thr...

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Polaris Sportsman 800 Big Boss, Owner'S Manual

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