Polaris Sportsman 800 EFI 4x4 2012, Service Manual

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2
2.5
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
REQUIRED MAINTENANCE INTERVALS
ITEM MAINTENANCE INTERVAL REMARKS
HOUR-
S
CALEN-
DAR
MILES (KM)
▶
, E
Engine oil change (break-in
period)
25 H 1 M
250 (400) Perform a break-in oil and filter change
▶ Front gearcase fluid
25 H 1 M
250 (400)
Initial fluid level inspection; change demand drive fluid if
exposed to extreme use.
***
▶
Middle gearcase fluid (if
equipped)
25 H 1 M
250 (400) Initial fluid level inspection
▶ Rear gearcase fluid
25 H 1 M
250 (400) Initial fluid level inspection
▶
Transmission fluid 25 H 1 M
250 (400) Initial fluid level inspection
▶ , E
Engine breather filter (if
equipped)
25 H 1 M
250 (400) Inspect; replace if necessary
▶
General lubrication 50 H 3 M
500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage
50 H 6 M
500 (800) Inspect, lubricate, adjust
■
Steering
50 H 6 M
500 (800)
Lubricate
▶ Front Suspension
50 H 6 M
500 (800)
Lubricate
▶
Rear Suspension
50 H 6 M
500 (800)
Lubricate
■, E
Throttle Cable/TRS Switch 50 H 6 M
500 (800) Inspect; adjust; lubricate; replace if necessary
E Air intake ducts 50 H 6 M
500 (800) Inspect ducts for proper sealing/air leaks
Drive belt 50 H 6 M
500 (800) Inspect; adjust; replace as needed
Cooling system (if
applicable)
50 H 6 M
500 (800)
Inspect coolant strength seasonally; pressure test system
yearly
▶ , E Engine Oil Change
100 H 6 M
1000 (1600)
Perform a break-in oil change at 25 hours or after one
month of operation
▶
, E Oil filter change
100 H 6 M
1000 (1600) Replace with oil change
▶ Front gearcase fluid
100 H 12 M
1000 (1600) Change fluid; also refer to 25 H interval
▶
Middle gearcase fluid
(if equipped)
100 H 12 M
1000 (1600) Change fluid
▶ Rear gearcase fluid
100 H 12 M
1000 (1600) Change fluid
▶
Transmission fluid 100 H 12 M
1000 (1600) Change fluid
*** Service Note: Under extreme use, change demand drive fluid every 25 hours. “Extreme Use” is defined as constant ADC operation on hilly or
mountainous terrain, or if ADC is the primary mode of operation.
▶ = Perform these procedures more often for vehicles subjected to severe use.
E = Emission Control System Service (California)
■ = Have an authorized Polaris Dealer perform these services.
MAINTENANCE