Polaris Sportsman 800
POLARIS SPORTSMAN 800 4x4 & 800 6x6 (2012-2014) - WORKSHOP MANUAL - WIRING SCHEMATICS
POLARIS SPORTSMAN 800 4x4 & 800 6x6 (2012-2014) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS - English Workshop Manual and Wiring Schematics, for ATVs Polaris Sportsman 800 4x4 & 800 6x6 (2012-2014). INDEX: 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 SCHEMATICS
Polaris Sportsman 800 4x4 & 800 6x6 (2012-2014) - Workshop Manual, Repair Manual - Wiring Schematics
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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