Instruction/ maintenance manual of the product 800 6X6 Polaris
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For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No.
W A RNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth defects or other reproductive harm.
1 WELCOME Thank you for purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line o f utility and recreati onal products.
2 POLARIS and POLARIS TH E W A Y OUT are registered t rademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard.
5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicle s, such as motorcycles and cars.
6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your k e y number) and mating it with one of yo ur existing keys.
7 SAFETY Safety T raining Safety training is a top p riority for Polaris. When you purchased your new vehicle, your dealer i nstru cted you o n the authorized A TV Rider- Course sm available to you and your eligib le family members. This train- ing is included in the purchase price of your vehicle.
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. W ear pro- tective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.
10 SAFETY Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manu al. See the OPERA TION section of the owner ’s manual for proper operating proce dures.
11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventilated area.
12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).
13 SAFETY Safety W arnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn.
14 SAFETY Safety W arnings Physical Control of the V ehicle Removing a hand from the handlebars or feet from the footrests during operatio n can reduce your abili ty to control th e vehicle or cause loss of balance and ejection from the vehicle.
15 SAFETY Safety W arnings Descending Hill s Improper ly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hi ll s as de scri b ed in the owner's manual. NOTE: A special technique i s required when braking while traveling down- hill.
16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, rolling backwards or improperl y dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed whe n climbing a hill. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or desce ndi ng a hill.
17 SAFETY Safety W arnings Operating on Steep Hills Operating on exce ssively steep hills co uld cause an overturn. Never operate on hills too steep for the vehicle or for your abilities.
18 SAFETY Safety W arnings Improper Tire Maintenance Operating this vehicle with improper tires or with impro per or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
19 SAFETY Safety W arnings Improper Cargo Loading Overloading the vehicl e or carryi ng/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this vehicle.
20 SAFETY Safety W arnings Operating Through Deep W ater Operating the vehicle through deep o r fast-flowing water could cause the ti res to float, causing loss of control or overturn.
21 SAFETY Safety W arnings Operating a Damaged V ehicle Operating a damaged vehicle can result in an acciden t. After any overturn or accident, have a qualifi ed service dealer inspect the entire ma chine for possible damage, including (but not limited to) brakes, th rottle and steering systems.
22 SAFETY Safety Labels and Locations W arn ing labels have been plac ed on the vehicle for your protectio n. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this ma nual dif fer from the labels on your vehicle, always re ad and follow the instructions of the labels on the vehicle.
23 SAFETY Safety Labels and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause loss of co ntrol. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.
24 SAFETY Safety Labels and Locations Cont ainer/No Passenger Warning W ARNIN G Remove flammable containers from box before refueling. W ARNIN G • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers. Maximum Box Load 800 lbs.
25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are unde r the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7172588 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard.
26 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter sy s t em .T o gain additional wheel speed while backing, release the throttle and depress the override button.
27 FEA TURES AND CONTROLS Switches 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. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights.
28 FEA TURES AND CONTROLS Throttle Lever Operating this vehicle with sticking or improperly operatin g throttle controls could cause an accident. Never start or ope rate the vehicle if it has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle.
29 FEA TURES AND CONTROLS Brake Systems Aggressively applying the rear brake wh en backing down a hill may cause rear tipover , which could result in seriou s injury or death. N ever back down a hill. Use caution when ap plying the rear brake. Do not aggressivel y apply the rear brake when going forward.
30 FEA TURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti- vated disc brake s. Always test brake lever travel and master cylinder fluid level before riding.
31 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid An over-full master cyl inder may cause brake drag or brake l ock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid.
32 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in park. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever .
33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .
34 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wheel Drive syst em is controlled by the 4X4 (A WD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline.
35 FEA TURES AND CONTROLS All Wheel Drive System Engaging A WD The 4X4 switch may be turned on or off while the vehicle is movin g. Initially , the vehicle's electronic sy stem will not enable A WD until the engine RPM is below 310 0. Once en abled, A WD remain s enabled until the 4X4 switch is turned off.
36 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC sys tem (if eq uippe d) allows engi ne braking to all fou r wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascen ding or descending a hill.
37 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.
38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.
39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center St andard Modes Use the MODE button to toggle thro ug h the mode options. The reverse override button is also the MODE bu tton. See page 26. The transmis sion cannot be in reverse wh en using this feature.
40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode.
41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge ind icates whether or not current is flowing through the all- wheel-drive coil.
42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1.
43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your Polaris dealer fo r all major repairs. See page 45 for Blink Co des and Failu re Descriptions.
44 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (inj ector , fuel pump, etc.
45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Descript ion 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor H.
46 OPERA TION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual.
47 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks.
48 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
49 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. See page 7. 2. Do not allow anyone und er 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle.
50 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ride. Fin d out where the de signated riding areas are by con- tacting your Polaris dealer , a local rid ing club or local officials.
51 OPERA TION S tarting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in park. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged.
52 OPERA TION Driving Procedures 1. W ea r a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5.
53 OPERA TION T urning the V ehicle Y our vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction slightly .
54 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas.
55 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill.
56 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1.
57 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. A void steep hills (25 ° maximum). 3. Shift body weight uphill.
58 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill.
59 OPERA TION Driving Through W ater Y our vehicle can operate through water with a maximum recommended de pth equal to the bottom of the footrests. Fol- low these procedures w hen operating through water: 1. Determine water depths and current before entering water .
60 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating 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.
61 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brake s lightly for stopping. 5. A void turning at sharp angles.
62 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo imp roperly can alte r vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: • Never exceed the maximum weight capacity of the vehicle.
63 OPERA TION Hauling Cargo 1. Always read and understand th e load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owne r's manual and on the safety labels.
64 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check car go distribution. If car go has shifted to the rear of the box, exercise caution.
65 OPERA TION Parking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Always block the rear wheels on th e downhill side.
66 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
67 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main ten a nc e ch art.
68 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a could re sult in component failure and ca use an accident, which may result in seri ous injury or death. Always have an authorized Pola ris de aler perform these services.
69 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - Weekly - Inspect; replace as needed X Q Br.
70 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services.
71 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 67.
72 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil.
73 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface.
74 MAINTENANCE Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o -ring is in good condition. 1 1. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.
75 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the interval s outlined in the Periodic Mainte- nance Chart beginning on page 67 . Maintain the oil le vel at the bottom of the fill plug hole. The fill plug is located on the right side of the A T V beh ind the footwell.
76 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 67. W e rec- ommend the use of Demand Drive L T Premium Fluid . Use of other fluids may result in improper operation of components.
77 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the 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 .
78 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the in tervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain th e fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz.
79 MAINTENANCE Middle Gearcase Oil Always check and change the mid- dle gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart begin ning on page 67. W e rec ommend the use of Pola ris A TV Angle Drive Fluid (or GL5 80-90 weight gear lube).
80 MAINTENANCE Active Descent Control (ADC) Fluid If your vehicl e is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fl uid and ADC fluid).
81 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level su rface. 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 differential).
82 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
83 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s 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 coo ling system has been drained for maintenance or repair .
84 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops. If the fluid le ve l is low and the diaphragm is not extended, a leak is likely and the dia phragm should be repla ced.
85 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result from improper toe alignment and adjustment.
86 MAINTENANCE S teering Assembly The steering as sembl y of the vehicle should be checked periodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicle. Side Panel Re moval 1.
87 MAINTENANCE Ti r es Operating your vehicle with worn tires, i mproperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling an d could cause an accident resulting in serious injury or death. Alwa ys follo w all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle.
88 MAINTENANCE Ti r es Wheel Inst allatio n 1. Place the transmission in park. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t o ward forward rotation. 4. Install the wheel nuts and finger-tighten them.
89 MAINTENANCE 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 . W ash the pre-filter in soapy water , then rinse and let dry .
90 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the top of the access door .
91 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and replace burn ed out lamps promptly . Always make sure lights are adjusted properly for best visibility .
92 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall .
93 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or do wnward. 1. Loosen the phillips screw located at the rear o f the headlamp.
94 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r 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 disconn ect the speedometer harnes ses from the speedometer .
95 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headlamp . 3. Reinstall the harness assembly into the headlight assembly .
96 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendatio ns Refer to the specifications sect ion beg inn ing on pa ge 1 22 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
97 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection Normal Sp ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
98 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impo ssible to take your vehicle to a dealer before starting it, fo llow the steps outlined below .
99 MAINTENANCE S park Arrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves.
100 MAINTENANCE P V T System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced.
101 MAINTENANCE P V T System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
102 MAINTENANCE P V T System When T o Use Low Range and High Range PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface.
103 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , a lways connect the negative (black) cable last.
104 MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last.
105 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 107 before installing the battery .
106 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to mainta in a full charge.
107 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly t e du ring charging. See page 104. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating.
108 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge Time (Using constant current charger @ standa rd amps specifie d on to p o f ba t t er y) 100% 12.
109 MAINTENANCE Cleaning and St orage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. NOTICE: High water pressure may damage comp onents. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.
110 MAINTENANCE Cleaning and St orage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution.
111 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
112 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S tarting the engine during the storage period will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and then clean the vehic le as recommended.
113 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommended in the Periodic Maintenance Char t beginning on page 67.
114 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 67. Battery Maintenance Remove the battery and rechar ge it as outlined on page 107.
115 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top 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 vehicle to the transporting unit securely with suitable straps or rope.
116 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Springs The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counterclockwise to increase or decrease spring tension. Always adjust all rear springs to equal settings.
117 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Pola ris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1.
118 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 58).
119 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Recharge th e battery to 12.
120 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timi.
121 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fu.
122 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sport sman Big Boss 6X6 800 EFI Maximum W eight Capacity 1 1 15 lbs. ( 507 kg) (includes operator, car go, accessories) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.
123 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment Sport sman Big Boss 6X6 800 EFI T r ansm ission Automatic PVT with E-Z Shift H/ L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.1 1:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.
124 POLARIS PRODUCTS Part Number Description Engine Lubr icant 2870791 Fogging Oi l (12 oz. Aerosol) 2876244 PS-4 PLU S Per formance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performan ce Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / T ransmission Lu bricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (q t.
125 W ARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris Light Utilit y V ehicle against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
126 W ARRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
127 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARRANTY .
128 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA - TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.
129 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, a ll warranty coverage will be denied.
130 W ARRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Of f Road Utility V ehicle (ORUV) emissions limited warranty is in additi on to the Polaris st andard limited warrant y for this vehicle.
131 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me you r vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
132 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS.
133 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS.
An important point after buying a device Polaris 800 6X6 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 800 6X6 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 800 6X6 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 800 6X6 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 800 6X6 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 800 6X6, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 800 6X6.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 800 6X6. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 800 6X6 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
