Polaris Sportsman 800 4x4 & 800 6x6 (2012-2014) - Service Manual, Repair Manual - Wiring Diagrams

POLARIS SPORTSMAN 800 4x4 & 800 6x6 (2012-2014) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for ATVs Polaris Sportsman 800 4x4 & 800 6x6 (2012-2014).

 
CONTENTS:

MODEL INFORMATION
-Model Number Designation
-Vehicle Identification Number (Vin) Designation
-Engine Number Designation
-Vin And Engine Serial Number Location
-Transmission Serial Number Location


GENERAL INFORMATION

-Sportsman 800 Efi 4x4 Specifications
- 2012-2014 Sportsman 800 Efi
-Sportsman 800 Efi Big Boss 6x6 Specifications
- 2012–2014 Sportsman 800 Efi Big Boss 6x6
-Publications / Paint Codes / Keys / Tools
- Publications
- Paint Codes
- Special Tools
- Replacement Keys
-Misc. Numbers/Charts
- Conversion Table
- Sae Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- Decimal Equivalents


MAINTENANCE

-Lubricants / Service Products
- Polaris Lubricants, Maintenance And Service Products
-Special Tools
-Overview
-Periodic Maintenance Chart
-Lubrication / Fluids
- Pre-Ride / Daily Inspection
- Lubrication / Grease Points (4x4)
- Lubrication / Grease Points (6x6)
- Engine Oil Level
- Oil/Filter Change
- Front Gearcase Lubrication (4x4)
- Front Gearcase Lubrication (6x6)
- Adc Differential Hydraulic Circuit Fluid Change (6x6)
- Transmission Lubrication (4x4)
- Transmission Lubrication (6x6)
- Middle Gearcase Lubrication (6x6)
- Rear Gearcase Lubrication (6x6)
-Vehicle Inspection
- Shift Link Rod Inspection (4x4)
- Shift Link Rod Inspection (6x6)
- Throttle Inspection
- Throttle Cable / Throttle Release System (Trs Switch) Adjustment
- Fuel System
- Vent Lines
- Compression Test
- Engine Mounts
- Spark Plug
- Battery Maintenance
- Cooling System
- Coolant Strength / Type
- Cooling Hoses
- Radiator
- Cooling System Pressure Test
- Reservoir Level Inspection
- Radiator Coolant Level
- Radiator/Grill Screen
- Air Filter/Pre-Filter Service
- Air Box Sediment Tube
- Engine Breather Hose
- Pvt Inspection / Drying Procedure
- Engine Ground
- Camber/Caster
- Steering Inspection
- Tie Rod / Steering
- Wheel Alignment
- Toe Alignment
- Exhaust Pipe
- Brake System Inspection
- Brake Pads
- Brake Hose Inspection
- Auxiliary Brake Testing
- Auxiliary Brake Adjustment
- Suspension: Spring Preload Adjustment
- Front Suspension
- Rear Suspension
- Cv Shaft Boot Inspection
- Atv Controls
- Wheel Inspection
- Frame, Nuts, Bolts, Fasteners
- Wheel Removal: Front Or Rear
- Wheel Installation
- Tire Pressure
- Tire Inspection


ENGINE

-Specifications
- Crankcase Exploded Views
- Engine Fastener Torque Patterns
- Torque Specifications
- 800 Efi Engine Service Specifications
-General Engine Service
- Accessible Components
- Piston Identification
- Cooling System Specifications
- Cooling System Pressure Test
- Coolant Air Bleeding Procedure
- Engine Removal (Typical)
- Engine Installation Notes
- Cylinder Hone Selection And Honing Procedure
- Honing To Deglaze
- Cleaning The Cylinder After Honing
- Oil Flow Chart
- Engine Lubrication Specifications
- Oil Pressure Test
-Engine Disassembly And Inspection
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Push Rods
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp
- Valve Seal/Spring Service (On Engine)
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Reassembly
- Valve Sealing Test
- Cylinder Removal
- Valve Lifter Removal/Inspection
- Piston Removal
- Cylinder Inspection
- Piston-To-Cylinder Clearance
- Piston/Rod Inspection
- Piston Ring Installed Gap
- Starter Drive/Bendix Removal Inspection
- Flywheel / Stator Removal / Inspection
- Engine Crankcase Disassembly / Inspection
- Camshaft Inspection
-Engine Reassembly
- Crankcase Reassembly
- Flywheel / Stator Installation
- Cylinder Head Installation
-800 Efi Exhaust System
- Exhaust Layout
-Troubleshooting
- Engine
- Cooling System


FUEL SYSTEM - GENERAL

-General Information
- Service Notes
- Efi System Exploded View
- Efi System Component Locations
- Diagnostic Connector And Fuses
- Fuel Tank Assembly
- Fuel Lines - Quick Connect
-Electronic Fuel Injection
- Principal Components
- Efi Operation Overview
- Initial Priming / Starting Procedure
-Electronic Control Unit (Ecu)
- Operation Overview
- Ecu Service
- Ecu Replacement
-Fuel Pump
- Operation Overview
- Fuel Pump Test
- Fuel Pump / Tank Assembly Replacement
-Fuel Sending Unit
- Fuel Sending Unit Test
- Fuel Pump Replacement
-Fuel Tank Vent Routing
- Fuel Tank Vent Hose Routing
-Fuel Pressure Regulator
- Operation Overview
- Fuel Pressure Regulator Test
- Fuel Pressure Regulator Replacement
-Fuel Injectors
- Operation Overview
- Fuel Injector Service
- Fuel Injector Replacement
-Crankshaft Position Sensor (Cps)
- Operation Overview
- Crankshaft Position Sensor Test
- Crankshaft Position Sensor (Cps) Replacement
-Temperature / Barometric Air Pressure Sensor (T-Bap)
- Operation Overview
- Temperature And Barometric Air Pressure Sensor Test
- Temperature And Barometric Air Pressure Sensor Replacement
-Throttle Position Sensor (Tps)
- Operation Overview
- Tps Learn Function
- Throttle Position Sensor Test
- Throttle Position Sensor Replacement
- Throttle Position Sensor Adjustment
-Engine Temperature Sensor
- Operation Overview
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
-Ignition Coil
- Operation Overview
- Ignition Coil / Ht Lead Replacement
- Ignition Coil Tests
-Digital Wrench® Operation
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Also Refer To Page 3.2)
- Diagnostic Software Version
- Guided Diagnostic Available
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Digital Wrench® Serial Number Location
- Digital Wrench® Version And Update Id
- Digital Wrench® Updates
- Digital Wrench® Feature Map
- Ecu Replacement
- Engine Controller Reprogramming (Reflash)
-Troubleshooting
- Diagnostics Using “Blink Codes”
- Efi Circuit - Power On
- Efi Circuit - Crank Position Sensor
- Efi Circuit - Fuel Pump
- Efi Circuit - Throttle Position Sensor
- Efi Circuit - Temperature - Barometric Air Pressure Sensor
- Efi Circuit - Engine Temperature
- Efi Circuit - Malfunction Indicator Light
- Efi Troubleshooting


BODY / STEERING / SUSPENSION

-General Information
- Torque Specifications
- Multi-Function Pliers
- Decal Replacement
-Body
- Side Panel Removal
- Front Storage Box Lid / Front Rack And Access Panel Removal / Installation
- Foot Well Removal / Installation
- Front Bumper Removal / Installation
- Mud Guard Removal / Installation
- Front Fender Removal/Installation
- Front Rack / Storage Box Lid Assembly (4x4 And 6x6)
- Front Cab Assembly (4x4 And 6x6)
- Front Bumper Assembly (4x4 And 6x6)
- Rear Rack Assembly (4x4)
- Rear Cab And Seat Assembly (4x4)
- Rear Storage Box Assembly (4x4)
- Headlight Pod Exploded View
- Winch And Front Bumper Mounting (4x4 And 6x6)
- Rear Fender Panel Removal / Installation (6x6)
- Rear Body Assembly Exploded View (6x6)
- Frame / Bumper / Front Rack (6x6)
-Steering
- Handlebar Block Installation Procedure
- Steering / A-Arm Exploded View
- A-Arm Replacement
- Ball Joint Replacement
- Steering Post Removal
- Steering Post Assembly
-Suspension
- Front Strut Cartridge Replacement
- Strut Assembly
- Rear Suspension Exploded View (4x4)
- Torsion Bar Exploded View (4x4)
- Rear / Middle Suspension Exploded View (6x6)
- Rear Torsion Bar Assembly (6x6)
-Cargo Box 6x6
- Removal / Installation (6x6)


PVT SYSTEM OVERVIEW

-Special Tools And Supplies
-Pvt System Fastener Torques
-Clutching Charts
-General Operation
-Drive Clutch Operation
-Driven Clutch Operation
-Pvt Break-In (Drive Belt / Clutches)
-Maintenance / Inspection
-Overheating / Diagnosis


CLUTCHING

-Pvt System Service
- Disassembly
- Assembly
-Drive Belt
- Belt Removal
- Belt Installation
- Belt Inspection
- Pvt Break-In (Drive Belt / Clutches)
-Clutch Alignment
- Clutch Alignment Tool Use
- Setting Center-To-Center Distance
-Drive Clutch Service (4x4 - Non Ebs)
- Exploded View (Non Ebs)
- Clutch Disassembly
- Shift Weight Inspection
- Spider Removal
- Button To Tower Clearance Inspection
- Bearing Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Clutch Assembly
-Ebs Drive Clutch Service (6x6)
- Ebs Drive Clutch Exploded View (6x6)
- Drive Clutch Disassembly
- Shift Weight Inspection
- Spider Removal
- Button To Tower Clearance Inspection
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- One-Way Clutch Inspection (Ebs Drive Clutch)
- Drive Clutch Reassembly
-Drive Clutch Bushing Service (Non Ebs And Ebs)
- Bushing Service
-Driven Clutch Service (Non Ebs)
- Exploded View (Non Ebs)
- Clutch Disassembly / Inspection
- Clutch Assembly
-Driven Clutch Service (Ebs)
- Driven Clutch Exploded Views (Ebs)
- Clutch Disassembly
- Clutch Assembly
-Driven Clutch Bushing Service
- Driven Clutch Bushing Service (Non Ebs And Ebs)
-Troubleshooting


FINAL DRIVE

-Specifications
- Torque Table
- Gearcase Fluid / Capacity
-Front Hub
- Disassembly
- Assembly
-Front Gearcase Removal And Installation (Adc And Non Adc)
- Gearcase Removal
- Gearcase Installation
-Front Gearcase - Centralized Hilliard Non Adc (4x4)
- Operation Non Adc
- Disassembly / Inspection Non Adc
- Reassembly / Inspection Non Adc
- Front Gearcase Diagnosis
- Setting Ring Gear Backlash Non Adc
-Front Gearcase - Centralized Hilliard Adc (6x6)
- Operation
- Adc Gearcase Exploded View
- Adc Operation
- Front Gearcase Diagnosis
- Coil Testing
- Adc Differential Hydraulic Circuit Bleeding
- Disassembly / Inspection
- Adc Gearcase Piston Replacement Procedure
- Assembly
- Setting Ring Gear Backlash
-Middle Gearcase (6x6)
- Removal
- Disassembly And Inspection
- Reassembly
- Installation
- Middle Gearcase Exploded View
-Front Drive (Cv) Shaft
- Inspection
- Removal
- Installation
-Rear Hub
- Removal
- Disassembly
- Assembly
- Installation
-Rear Drive (Cv) Shaft
- Inspection
- Removal
- Installation
-Rear Gearcase (6x6)
- Removal
- Disassembly And Inspection
- Reassembly
- Installation
- Rear Gearcase Exploded View (6x6)
-Cv Drive Shaft Service
- Drive Shafts And Propshafts Components
- Drive Shaft And Cv Joint Handling Tips
- Outer Cv Joint / Boot Replacement
- Outer Cv Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded Views
-Prop Shaft - Front Or Rear
- Removal And Installation
-U-Joint Service
- Disassembly
- Assembly


TRANSMISSION

-General Information
- Torque Specifications (4x4)
- Lubrication
-Transmission Service (4x4)
- Transmission Frame Mounts
- Transmission Upper Frame Mount
- Transmission Rear Stabilizer Mounts
- Transmission Control Arm Bracket Mounts
- Shift Linkage Inspection
- Gear Selector Removal
- Transmission Removal
- Transmission Installation
- Troubleshooting Checklist
- Transmission Disassembly
- Snorkel / Output Gear Backlash Procedure
- Transmission Assembly
-Transmission Service (6x6)
- Torque Specifications
- Lubricant / Capacity
- Transmission Removal
- Disassembly
- Assembly
- Transmission Installation (6x6)
- Troubleshooting
-Transmission Exploded View (4x4)
- Sportsman Transmission Exploded View (4x4)
-Transmission Exploded View (6x6)
- Sportsman Transmission Exploded View (6x6)


BRAKES

-Specifications
- Special Tools
- Torque Table
- Component Service Limits
-Brake System Exploded View (4x4)
- Brake System Exploded View
-Brake System Exploded View (6x6)
- Brake System Exploded View
-Brake Caliper Explioded Views
- Front Brake Caliper Assembly
- Rear Brake Caliper Assembly
-Hydraulic Brake System
- Operation Overview
- Brake Noise Troubleshooting
- Brake Bleeding / Fluid Change
-Front Master Cylinder
- Removal
- Installation
-Front Brake Pads
- Pad Removal
- Assembly
- Brake Burnishing Procedure
-Front Brake Disc
- Inspection
- Removal / Replacement
-Front Caliper
- Removal
- Inspection
- Reassembly
- Installation
-Rear Brake Pad
- Rear Pad Removal
- Rear Pad Installation
- Brake Burnishing Procedure
-Rear Caliper
- Removal And Inspection
- Assembly
-Rear Brake Disc
- Inspection
-Troubleshooting
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
-Rear Master Cylinder
- Overview
- Rear Master Cylinder Removal / Installation
- Pedal Removal / Installation


ELECTRICAL

-General Information
- Special Tools
-Instrument Cluster
- Overview
- Instrument Cluster Diagnostic Mode
- Setting A New Service Interval
- Efi Diagnostic Mode
- Speedometer Removal
- Speedometer Installation
-Speedometer Troubleshooting
- Test 1 - No All Wheel Drive
- Test 2 - No Display / Test 3 - No Reverse Speed Limit
- Test 4 - No Awd Hub Safety Limiter
- Test 5 - Reverse Speed Limiter / Test 6 - Speed Sensor
- Test 6 (4x4) - Vehicle Speed Sensor
- Speed Sensor Location 4x4
- Speed Sensor Testing
- Test 7 - No Fuel Gauge / Test 8 - Transmission Switch
-All Wheel Drive (Awd) Coil (4x4)
- Operation Overview
- Diagnosing System Failures
-Active Descent Control (Adc) Coil (6x6)
- Operation Overview
- Diagnosing System Failures
-Cooling System Components
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor
- Fan Motor Current Draw
-Gear Position Indicator Switch
- Test Diagram
-Throttle Release System (Trs) Switch
- Trs Switch Operation
- Trs Operation Test
-Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Alternator Output Test
- Charging System Testing Flow Chart
-Relays
- Operation
-Fuses/Circuit Breaker
- Operation
-Lighting
- High Beam Headlight Bulb Replacement
- Headlight Housing Replacement
- High Beam Headlight Adjustment
- Lower Headlamp Removal / Installation
- Low Beam Headlight Adjustment
- Headlamp Switch Test
- Brake Light Replacement (4x4)
- Brake Light Switch (4x4)
- Brake Light Switch (6x6)
- Brake Lamp/Tail Lamp Replacement (6x6)
-Fuel Sender
- Testing
-Accessory Power
- Wire Connections
-Starter System
- Starter Lockout Overview And Diagnostic
- Troubleshooting
- Voltage Drop Test
- Starter Solenoid Bench Test
- Starter Motor Removal
- Starter Installation
- Starter Drive
- Starter Exploded View
-Starter System Testing Flow Chart
- Flow Chart
-Battery
- Battery Identification
- Battery Conductance Analyzer
- Battery Activation (Conventional)
- Battery Terminals/Bolts
- Conventional Battery Inspection / Removal
- Conventional Battery Installation
- Conventional Battery Testing
- Conventional Battery Ocv - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Battery Load Test
- Off Season Storage
- Charging Procedure
- Low Maintenance Battery
- Low Maintenance Battery Charging
- Low Maintenance Battery Inspection / Removal
- Low Maintenance Battery Installation
- Low Maintenance Battery - Ocv- Open Circuit Voltage Test
- Low Maintenance Battery Load Test
- Low Maintenance Battery Charging Procedure
- Low Maintenance Battery Off-Season Storage
-Troubleshooting Diagrams
- Overview
- All Wheel Drive - Efi
- Charging Circuit - Efi
- Cooling Fan - Efi
- Fuel Pump - Efi
- Gear Switch - Efi
- Power Circuit - Efi
- Reverse Override - Efi
- Fan Control - Efi
- Start Circuit - Efi
- Start Enable - Efi

INDEX
WIRING DIAGRAMS