Polaris Sportsman 800 Big Boss Manuale Utente

7SAFETYSafety TrainingSafety training is a top priority for Polaris. When you purchased your new vehicle, your dealer instructed you on the authorized

97MAINTENANCESpark PlugsSpark Plug InspectionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion depos

98MAINTENANCEVehicle ImmersionIf your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the ve

99MAINTENANCESpark ArrestorFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never ru

100MAINTENANCEPVT SystemFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of th

101MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed in

102MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

103MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

104MAINTENANCEBatteryBattery Removal1. Remove the seat.2. Disconnect the battery hold-down strap.3. On conventional batteries, remove the battery vent

105MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

106MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

8SAFETYSafe Riding GearAlways wear appropriate clothing when riding this vehicle. Wear pro-tective clothing for comfort and to reduce the chance of in

107MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

108MAINTENANCEBatteryBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVo

109MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

110MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

111MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

112MAINTENANCECleaning and StorageStorage TipsNOTICE: Starting the engine during the storage period will disturb the protective film created by foggin

113MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance

114MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

115MAINTENANCETransporting the VehicleFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in park.3. Lo

116ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Rear SpringsThe rear shock absorber springs are adjusted by rotating the adjus

9SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sha

117ADJUSTMENTSThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris deal

118TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

119TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

120TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

121TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

122SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman Big Boss 6X6 800 EFIMaximum Weight Capacity 1115 lbs. (507 kg) (includes operator, cargo,

123SPECIFICATIONSClutching*EBS models require no helix/spring adjustmentSportsman Big Boss 6X6 800 EFITransmission Automatic PVT with E-Z Shift H/L/N/

124POLARIS PRODUCTS Part NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oi

125WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

126WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

10SAFETYFailure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury o

127WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

128WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

129WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

130WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

131MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

132MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

133MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

11SAFETYSafety WarningsHandling GasolineGasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve

12SAFETYSafety WarningsProtective ApparelRiding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a seri

13SAFETYSafety WarningsOperating on PavementOperating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adve

14SAFETYSafety WarningsPhysical Control of the VehicleRemoving a hand from the handlebars or feet from the footrests during operation can reduce your

15SAFETYSafety WarningsDescending Hills ImproperlyImproperly descending a hill could cause loss of control or overturn.• Always follow proper procedur

16SAFETYSafety WarningsStalling While Climbing a HillStalling, rolling backwards or improperly dismounting while climbing a hill could cause an overtu

For your nearest Polaris dealer, call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340Phone 1-888-70

17SAFETYSafety WarningsOperating on Steep HillsOperating on excessively steep hills could cause an overturn.Never operate on hills too steep for the v

18SAFETYSafety WarningsImproper Tire MaintenanceOperating this vehicle with improper tires or with improper or uneven tire pressure could cause loss o

19SAFETYSafety WarningsImproper Cargo LoadingOverloading the vehicle or carrying/towing cargo improperly may cause changes in handling, which could ca

20SAFETYSafety WarningsOperating Through Deep WaterOperating the vehicle through deep or fast-flowing water could cause the tires to float, causing lo

21SAFETYSafety WarningsOperating a Damaged VehicleOperating a damaged vehicle can result in an accident. After any overturn or accident, have a qualif

22SAFETYSafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels

23SAFETYSafety Labels and LocationsTire Pressure/Load WarningWARNINGImproper tire pressure or overloading can cause loss of control. Loss of control c

24SAFETYSafety Labels and LocationsContainer/No Passenger WarningWARNINGRemove flammable containers from box before refueling.WARNING• Passengers can

25SAFETYSafety Labels and LocationsAge 16 WarningWARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or de

26FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchThis vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed

WA RNINGThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive

27FEATURES AND CONTROLSSwitchesEngine Stop SwitchMove the stop switch either left or right to the OFF position to stop the engine quickly. The engine

28FEATURES AND CONTROLSThrottle LeverOperating this vehicle with sticking or improperly operating throttle controls could cause an accident. Never sta

29FEATURES AND CONTROLSBrake SystemsAggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in seriou

30FEATURES AND CONTROLSBrake SystemsService Brake LeverSqueeze the service brake lever (left lever) toward the handlebar to apply the front and rear b

31FEATURES AND CONTROLSMaster Cylinder/Brake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an acciden

32FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in park.2. Squeeze and release the brake lever two or three tim

33FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle. H: High GearL:

34FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemThe All Wheel Drive system is controlled by the 4X4 (AWD) switch.ADC 4X4 Mode (if equipped)When the

35FEATURES AND CONTROLSAll Wheel Drive System Engaging AWDThe 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle&a

36FEATURES AND CONTROLSActive Descent Control (ADC) SystemThe ADC system (if equipped) allows engine braking to all four wheels when the vehicle desce

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURES AND CONTROLSInstrument ClusterYour vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In

38FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

39FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the MODE button to toggle through the mode options. The reverse ove

40FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

41FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

42FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

43FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesThe EFI diagnostic mode is for informational purposes only. Please s

44FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesCode DefinitionsOpen Load: There is a break in the wires that lead t

45FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesBlink CodeFailure Description12 BEGIN SEQUENCE22 Throttle Position S

46OPERATIONFailure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injur

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2008 Polaris Sales Inc. All information contained with

47OPERATIONBreak-In PeriodEngine and Drivetrain Break-in1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever han

48OPERATIONPre-Ride ChecklistFailure to inspect and verify that the vehicle is in safe operating condi-tion before operating increases the risk of an

49OPERATIONSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 7.2. Do not allow anyone under

50OPERATIONKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in

51OPERATIONStarting the Engine1. Position the vehicle on a level surface outdoors or in a well-venti-lated area. 2. Place the transmission in park.3.

52OPERATIONDriving Procedures1. Wear a helmet and eye protection. See page 8.2. Sit upright with both feet on the footrests and both hands on the hand

53OPERATIONTurning the VehicleYour vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the

54OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

55OPERATIONDriving UphillBraking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or

56OPERATIONDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . .

57OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or

58OPERATIONTurning Around on a Hill (K-Turn)If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.1.

59OPERATIONDriving Through WaterYour vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Fol-low

60OPERATIONDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2

61OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

62OPERATIONHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or bra

63OPERATIONHauling Cargo1. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outl

64OPERATIONHauling CargoDumping Cargo1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline

65OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

66EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

4INTRODUCTIONThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sy

67MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

68MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

69MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)XEAir filter,main element- Weekl

70MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service Have an

71MAINTENANCELubrication RecommendationsCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on p

72MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

73MAINTENANCEEngine OilOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on

74MAINTENANCEEngine OilOil and Filter Change10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring

75MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Mainte-nance Chart beginning on pa

76MAINTENANCEFront Gearcase (Demand Drive) FluidAlways check and change the demand drive fluid at the intervals out-lined in the Periodic Maintenance

5INTRODUCTIONFailure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This Polaris vehicle i

77MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Change1. Position the vehicle on a level surface. Remove the fill plug.2. Place a drain pan unde

78MAINTENANCERear Gearcase OilAlways check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on p

79MAINTENANCEMiddle Gearcase OilAlways check and change the mid-dle gearcase oil at the intervals outlined in the Periodic Mainte-nance Chart beginnin

80MAINTENANCEActive Descent Control (ADC) FluidIf your vehicle is equipped with Active Descent Control, there are two fluid levels that must be mainta

81MAINTENANCEActive Descent Control (ADC) FluidFluid Change1. Position the vehicle on a level surface. Before performing the fluid change, allow the v

82MAINTENANCECooling SystemThe engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recov

83MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain t

84MAINTENANCEBrakesFront/Rear/Middle BrakesThe front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting.Under normal o

85MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

86MAINTENANCESteering AssemblyThe steering assembly of the vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts ar

6INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

87MAINTENANCETiresOperating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehi

88MAINTENANCETiresWheel Installation1. Place the transmission in park.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem towa

89MAINTENANCEAir Filter1. 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

90MAINTENANCEFuse ReplacementIf the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace-ment. Loca

91MAINTENANCELightsPoor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. C

92MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustm

93MAINTENANCELightsLow Beam AdjustmentThe low beam can be adjusted slightly upward or downward.1. Loosen the phillips screw located at the rear of the

94MAINTENANCELightsHeadlight Housing Replacement1. Remove the two screws on the lower front corners of the headlight pod.2. Lift the pod slightly whil

95MAINTENANCELightsLower Headlamp Replacement1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the he

96MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 122 for the recom-mended spark plug type and g