2008 Polaris Sportsman 800 EFI Owners Manual
2008 Polaris Sportsman 800 EFI Manual
2008 Polaris Sportsman 800 EFI manual content summary:
- 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 1
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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 2
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2008 Sportsman 800 EFI Owner's Manual P/N 9921169 2 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 3
TABLE OF CONTENTS Know Your Vehicle ...5 Safety ...6 Features and Controls ...34 Operation ...54 Emission Control Systems ...71 Maintenance ...72 Adjustments ...120 Troubleshooting ...122 Polaris Products...126 Specifications ...127 Warranty ...129 Maintenance Log ...135 Index ...138 3 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 4
4 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 5
responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Vehicle Identification Numbers Record your vehicle - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 6
of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 7
rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information 7 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 8
SAFETY Safety Decals and Locations Rack Warning Age 16 Warning Rack Warning + + + + Clutch Cover Warning + "No Passenger" Warning "No Passenger" Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning WARNING - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 9
or forward flipover may result, especially in 4X4 (AWD). See Owner's Manual. All Wheel Drive Switch Do not push switch to engage 4X4 if the spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 10
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Gloves Long Pants Helmet Long Sleeves Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 11
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 12
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 13
priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 14
symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE A note will alert you to important information or instructions. 14 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 15
Safety WARNING SAFETY Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully, and follow the operating procedures described. • Never operate an ATV - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 16
weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible. • Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 17
trees. Always follow proper procedures when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. On slippery surfaces like ice . Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 18
SAFETY Operator Safety FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-3423764. Equipment Modifications We are concerned for the safety of our customers and for the general - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 19
WARNING SAFETY POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 20
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 21
Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 22
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/ - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 23
ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. 23 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 24
SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 25
loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 25 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 26
could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 44. Always check the terrain carefully before ascending any - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 27
proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling mastered the turning technique (on level ground) as described in the owner's manual. See page 66. Use extra caution when turning on any hill. Avoid - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 28
uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 66. 28 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 29
such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 30
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast- - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 31
tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and on safety decals. WARNING POTENTIAL HAZARD Operating installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 31 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 32
and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 33
SAFETY Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 34
FEATURES AND CONTROLS Switches Headlight Switch Work Light Switch (if equipped) 4X4 Switch Mode/Reverse Override Switch Main Key Switch Engine Stop Switch WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 35
Switches FEATURES AND CONTROLS Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. cal power to the vehicle, including lights. OFF RUN OFF NOTE: Both the main switch and the engine - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 36
to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 37
Brake Lever FEATURES AND CONTROLS Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 38
FEATURES AND CONTROLS Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 39
Parking Brake FEATURES AND CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Place the transmission in PARK. 2. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 40
FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 41
Fuel Tank Cap FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Automatic Transmission Gear Selector The transmission gear selector is - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 42
FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all 4X4 four wheels when the vehiSwitch cle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 43
All Wheel Drive System Engaging 4X4 FEATURES AND CONTROLS The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 44
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 45
Instrument Cluster FEATURES AND CONTROLS Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 46
Gear 2 P = Park 2. 4X4 Indicator - This 9 indicator illuminates when the 4X4 switch is 1 on either ADC 4X4 or 4X4. 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM too - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 47
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 48
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 49
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 each time the engine is started. When this - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 50
the button until the hours cycle back to zero. 5. When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed. Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 51
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 53 for Blink Codes and Failure Descriptions. Use the following procedure to download blink - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 52
FEATURES AND CONTROLS Instrument Cluster Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 53
Instrument Cluster Downloading Codes Blink Code 12 22 22 25 31 31 36 36 37 37 41 41 42 42 44 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 63 63 72 73 73 74 74 61 FEATURES AND CONTROLS Rider Information Center Failure Description BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 54
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 55
Break-In Period OPERATION The break-in period for your new Polaris ATV is the first ten 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 procedures for a proper break-in. Careful treatment of a new - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 56
OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Brake system/lever travel Brake fluid Auxiliary brake Front suspension Rear - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 57
Starting the Engine WARNING OPERATION Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lock the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 58
and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 59
with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 60
OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10. 2. Sit upright with both feet on the footrests and both hands 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 61
tire must slip traction slightly. To turn, steer 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 62
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose traction. 3. Maintain a high - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 63
injury or death. Avoid climbing steep hills (25° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 63 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 64
, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 65
straight downhill. 4. Slow down. 5. Squeeze the brake lever gradually. NOTE: Before operating your ATV, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 65 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 66
, or on the left if the vehicle 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 pointing across the hill or slightly - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 67
oil, and all grease fittings. CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 68
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 69
Driving Safely OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 70
OPERATION Driving Safely Parking on 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. 70 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 71
Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 72
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 RPM use • Prolonged low speed - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 73
Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 74
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 75
Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar X General lubrication Q Throttle Cable/ E ETC Switch MAINTENANCE Remarks Miles (Km) 500 (800) 500 (800) 500 (800) 500 (800) Lubricate all fittings, pivots, cables, etc. Inspect; adjust; lubricate; replace - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 76
(ADC models) X Fuel filter E Q Spark arrestor Q Toe adjustment 300 H 36 M - Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 77
Lubrication Guide MAINTENANCE Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Items not listed in the chart - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 78
MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 79
Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV. 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 completely, but do not lock it. NOTE: The dipstick must be - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 80
MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Always change the oil filter whenever changing oil. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 81
Engine Oil MAINTENANCE Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 82
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the ATV behind the footwell. The - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 83
Front Gearcase (Demand Drive) Fluid MAINTENANCE Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. We recommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of components - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 84
MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Maintain the fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill. The fill plug is - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 85
Rear Gearcase Oil Oil Change 1. 2. 3. 4. 5. 6. 7. 8. MAINTENANCE Position the vehicle on a level surface. Place a drain pan under the drain hole. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug with a new sealing washer. Torque to 14 ft. lbs. (19 Nm). - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 86
MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 83 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 87
Active Descent Control (ADC) Fluid Fluid Change MAINTENANCE 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 88
MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding ( - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 89
Cooling System Radiator Coolant MAINTENANCE To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 90
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 91
) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. 91 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 92
assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 93
described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. 2. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 94
tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 95
Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 96
normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove the screw from the rear - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 97
Lights MAINTENANCE High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 98
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 99
Lights MAINTENANCE Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 100
MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 127 for the recommended spark plug type and gap for your vehicle. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 101
will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 102
. Reinstall the plugs or install new plugs. 7. Attempt to start the engine. If necessary, repeat the drying procedure. 8. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 9. If water has been ingested into the PVT, follow the procedure on page - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 103
the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 104
PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 105
PVT System MAINTENANCE The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 106
There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the repeat the process. 7. Take the vehicle to your dealer for service as soon as possible. 106 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 107
Battery MAINTENANCE Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 108
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 109
has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 111 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 110
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 111
charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 112
MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 113
Cleaning and Storage Washing the Vehicle MAINTENANCE Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 114
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 vehicle. • Always - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 115
and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 116
. See page 113. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 117
time the fluid looks dark or contaminated) • Coolant (test strength) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs and - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 118
battery and recharge it as outlined on page 111. Store the battery in a cool, dry place. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. NOTE - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 119
Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place 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 ATV to the transporting unit securely with suitable straps or - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 120
in loss of control and possible serious personal 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. NOTE: Be sure the handlebars - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 121
Throttle Body/Idle RPM Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 122
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 123
Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections TROUBLESHOOTING Solution Recharge the battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 124
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 125
voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine TROUBLESHOOTING Solution Refuel, cycle key to ON position three times for 5 seconds each, then start Inspect and replace Replace with - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 126
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2876144 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 2870791 Description Engine Lubricant Fogging Oil (12 oz. - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 127
SPECIFICATIONS Sportsman 800 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 128
SPECIFICATIONS Sportsman 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Final Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 129
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 130
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 131
THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 132
must be done by an authorized Polaris dealer. If you move or are traveling 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 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 133
where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 134
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 135
MAINTENANCE LOG Present this 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 services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 135 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 136
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 136 - 2008 Polaris Sportsman 800 EFI | Owners Manual - Page 137
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1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
° Snowmobiles
°
All-terrain vehicles (ATVs)
°
RANGER
utility vehicles
°
Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we’ve ever produced.
For 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 interested in your
total satisfaction. Be sure to return to your dealership for all of your ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!