Polaris Sportsman 800 EFI 4x4 2012 User manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer®technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2013 (PN 9924864)
2012-2014 SPORTSMAN 800 / 6X6

COPYRIGHT INFO
All information contained within this publication is based on the latest product information at the time of publication. Due
to constant improvements in the design and quality of production components, some minor discrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly
prohibited. Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT(S) MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.

1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE
4
FUEL SYSTEM - GENERAL
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
9
BRAKES
10
ELECTRICAL

1
1.1
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
MODEL INFORMATION ..................................................................................1.2
MODEL NUMBER DESIGNATION..................................................................1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ........................................1.2
ENGINE NUMBER DESIGNATION .................................................................1.3
VIN AND ENGINE SERIAL NUMBER LOCATION ...................................................1.3
TRANSMISSION SERIAL NUMBER LOCATION ....................................................1.4
SPORTSMAN 800 EFI 4X4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
2012-2014 SPORTSMAN 800 EFI ..................................................................1.5
SPORTSMAN 800 EFI BIG BOSS 6X6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
2012–2014 SPORTSMAN 800 EFI BIG BOSS 6X6..................................................1.7
PUBLICATIONS / PAINT CODES / KEYS / TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
PUBLICATIONS....................................................................................1.9
PAINT CODES .....................................................................................1.9
SPECIAL TOOLS .................................................................................1.10
REPLACEMENT KEYS............................................................................1.10
MISC. NUMBERS/CHARTS.............................................................................1.11
CONVERSION TABLE ............................................................................1.11
SAE TAP / DRILL SIZES ..........................................................................1.12
METRIC TAP / DRILL SIZES ......................................................................1.12
STANDARD BOLT TORQUE SPECIFICATION.....................................................1.13
METRIC BOLT TORQUE SPECIFICATION ........................................................1.13
DECIMAL EQUIVALENTS .........................................................................1.14

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9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
MODEL INFORMATION
Model Number Designation
Example: A14KA09AD
GROUP MODEL
YEAR CHASSIS DRIVE-
LINE
ENGINE /
MOTOR CODE CATEGORY OPTION REGION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th
A 1 4 K A 0 9 A D
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
Vehicle Identification Number (VIN) Designation
Example: 4XAKA09A0E3000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CH-
AS-
SIS
DRI-
VE-
LIN-
E
EN-
GI-
NE
SIZ-
E
EN-
GI-
NE
MO-
DI-
FIE-
R
CA-
TE-
GO-
RY
CH-
EC-
K
DI-
GIT
MO-
DEL
YE-
AR
*
MF-
G.
LO-
CA-
TIO-
N
INDIVIDUAL SERIAL NO.
12345 6 7 8 9 10 11 12 13 14 15 16 17
4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014
GENERAL INFORMATION

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9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Engine Number Designation
EH076OLE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start
VIN and Engine Serial Number Location
The Vehicle Identification Number (VIN) and engine serial number are important for identification purposes. Whenever
corresponding about a Polaris utility vehicle, be sure to refer to the VIN and the engine serial number.
The machine VIN is stamped on the lower left side of the frame tube (A).
The engine serial number can be found on the sticker applied to the side of the cylinder head (B). An additional
identification number is stamped on the side of the crankcase beneath the oil filter (C).
GENERAL INFORMATION
1

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9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Transmission Serial Number Location
The transmission serial number is important for identification purposes. Whenever corresponding about a
transmission, be sure to refer to the transmission serial number.
The transmission ID is printed on a label located as shown below.
GENERAL INFORMATION