Polaris Sportsman 800 EFI User manual

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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Quadricycles
•RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2007 Polaris Sales Inc. 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. 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.
2008 Sportsman 800 Touring Quadricycle Owner’s Manual
P/N 9921454

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TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emission Control Systems . . . . . . . . . . . . . . . 64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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5
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protec-
tion of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number 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 key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key Number

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SAFETY
Rider Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.

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SAFETY
Rider Safety
Safety Training
When you purchased your new Quadricycle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa-
tion on a regular basis.
If you purchased a used Polaris Quadricycle from a party other than a
Polaris dealer, please request free safety training from any authorized
Polaris dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. Never allow anyone under 12 years of
age to ride as a passenger on this 2-up Quadricycle.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a
Quadricycle/trailer combination on public roads is prohibited. See your
Polaris dealer about configuring the vehicle to be certified to tow a
trailer on-road.
Equipment Modifications
The warranty on your Polaris Quadricycle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers and large racks may change vehicle han-
dling. Use only Polaris-approved accessories. Know their function and
effect on the vehicle.
WARNING
Failure to follow the warnings in this manual can result in serious injury or
death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A
collision or rollover can occur quickly, even during routine maneuvers, if you
fail to take proper precautions.
Read and understand your owner's manual and all warnings before operating
a Polaris Quadricycle.

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SAFETY
Rider Safety
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the Quadricycle.
Never operate a Quadricycle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Contact an authorized Polaris
Quadricycle dealer or visit the Polaris
web site at www.polarisindustries.com.
Never permit others to operate the Quadricycle unless they have read and
understand this manual and all product labels, and have completed a certified
safety training course.
Never allow anyone under 16 years
of age to operate this vehicle.
Never allow anyone under 12 years
of age to ride as a passenger on this
2-up Quadricycle.
Never carry more than one
passenger on this 2-up Quadricycle.
WARNING
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.

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SAFETY
Rider Safety
Always wear an approved helmet
that fits properly. Wear eye
protection (goggles or face shield),
gloves, boots, long sleeves and long
pants.
Never consume alcohol or drugs
before or while operating a
Quadricycle.
Never operate at excessive speeds.
Travel and turn at speeds
appropriate for the terrain, visibility,
operating conditions and your
experience.
Never attempt jumps or other stunts.

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SAFETY
Rider Safety
Always inspect your Quadricycle
before each use to verify that it's in
safe operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 43.
Keep both hands on the handlebars.
Keep both feet on the footrests.
A passenger should always be
seated in the passenger seat with
both feet on the footrests and both
hands on the passenger grab handles
at all times. The passenger should
never hold on to the operator.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on
rough, slippery or loose terrain.
Always follow the procedures
outlined in this manual for turning.
See page 47.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.