Polaris Sportsman BIG BOSS 6X6 800 EFI User manual

Polaris Defense Contact Information
Web: www.polarisdefense.com
E-mail: [email protected]
Phone: [phone]
Part No. 9921652 Rev 01
Printed in USA
Pantone 4645CVC

1
WELCOME
Welcome to our world-wide family of Polaris owners and operators!
At Polaris Defense, we are committed to our many war fighters around
the world. Our family of light tactical all-terrain vehicles are combat
proven, providing mobility, sustainability, transportability and mission
flexibility to our dismounted war fighters.
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
Polaris vehicle, making it one of the finest machines we’ve ever pro-
duced. For safe and enjoyable operation of your vehicle, be sure to fol-
low the instructions and recommendations in this owner’s manual.
This manual contains instructions for minor maintenance. Major main-
tenance and repairs are outlined in the Polaris Service Manual and
should be performed only by a factory-certified technician.
For sales, parts, technical information and support, please contact a
Polaris Defense representative.
Polaris Defense Contact Information
• Web: www.polarisdefense.com
• E-mail: [e-mail]
• Phone: [phone]
At Polaris, we are passionate about producing an exciting line of utility
and recreational products for our customers. We invite you to discover
your way out by becoming a proud owner of an award-winning
recreational vehicle from our huge family of Polaris vehicles.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER utility and recreational vehicles
• Victory motorcycles
You can find out more about Polaris by visiting our web site.
www.polarisindustries.com

2
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 Owner’s Manual P/N 9921652
MVRS 700 4X4/MVRS 700 6X6/MVRS 800 4X4/MVRS 800 6X6

3
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features and Controls . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 108
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 113
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
Refer to your service manual for vehicle specifications.
Vehicle Identification Numbers
Record your vehicle's identification numbers in the spaces provided.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements European directives
97/24/EC and 89/336/EEC.
VIN

5
SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may ride
as a passenger in this vehicle.
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
This vehicle handles differently than other vehicles, such as motorcycles and
cars. A collision or rollover can occur quickly, even during routine maneuvers
like turning, or driving on hills or over obstacles, if you fail to take proper
precautions.
Read and understand your owner's manual and all warnings before operating
the vehicle.

6
SAFETY
Operator 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.

7
SAFETY
Operator Safety
• Read this manual and all labels carefully. Follow the operating proce-
dures described.
• Never allow anyone without a valid driver's license to operate this
vehicle.
• Minimum age recommendation for passengers is five years old. Pas-
sengers under five years of age require special restraints which are
not available with this vehicle. Driver and passengers should wear
their seat belts at all times.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Helmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
• Never consume alcohol or drugs before or while operating this vehi-
cle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experi-
ence.
• Never attempt jumps or other stunts.
• Always inspect your vehicle each time you use it to make sure it's in
safe operating condition. Always follow the inspection and mainte-
nance procedures and schedules described in this manual.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.

8
SAFETY
Operator Safety
• Always follow proper procedures for turning as described in this
manual. Practice turning at slow speeds before attempting to turn at
faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized Polaris technician
if it has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for trav-
eling downhill and for braking on hills. Check the terrain carefully
before descending a hill. Never travel downhill at high speed. Avoid
going downhill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skid-
ding or sliding out of control.
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.
• Always use the proper size and type of tires specified for this vehicle,
and always maintain proper tire pressure.

9
SAFETY
Operator Safety
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and fol-
low the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
• Always keep arms and legs inside the cab frame while the vehicle is
in motion.
• Always engage the park brake before getting out of the vehicle. See
page 31.
• Always apply the service brakes before releasing the park brake.
• Always turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks.

10
SAFETY
Operator Safety
Equipment Modifications
Polaris does not recommend that consumers install any equipment to the
vehicle that may increase the speed or power of the vehicle, or make any
other modifications to the vehicle for these purposes. Any modifications
to the original equipment of the vehicle create a substantial safety haz-
ard and increase the risk of bodily injury.
The warranty on this vehicle is terminated if any equipment has been
added to the vehicle, or if any modifications have been made to the
vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling
characteristics of the vehicle. Use only Polaris-approved accessories,
and familiarize yourself with their function and effect on the vehicle.
WARNING
Make sure your vehicle is in excellent operating condition at all times. We
strongly recommend that the operator check all safety components before
each ride.
This vehicle is designed to provide safe operation when used as directed.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. The vehicle
may become unstable at speeds higher than those for which it is designed.
Loss of control may occur at higher speeds. Modifications may also create a
safety hazard and lead to bodily injury. Do not make any modifications to the
vehicle.

11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards while
climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when climbing
a hill.
If you lose all forward speed:
Apply the brakes.
Engage the park brake after fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service technician check the
complete vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.
WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle's tires are designed for off-road use only, not for use on
pavement. Paved surfaces may seriously affect handling and control of the
vehicle, and may cause the vehicle to go out of control.
Avoid operating the vehicle on pavement. If you must operate on a paved
surface, travel slowly and do not make sudden turns or stops.

12
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the
operator does not know how to operate the
vehicle properly in different situations and on
different types of terrain.
All operators must read and understand the
Owner's Manual and all warning and instruction labels before operating the
vehicle.
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, including
dirt or gravel.
In many states it's illegal to operate vehicles of this type on public streets,
roads and highways.

13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle after consuming alcohol
or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving this vehicle requires your full attention. DO NOT drink alcohol or use
drugs or medications before or while driving. They will reduce your alertness
and slow your reaction time. In most states and provinces, it's prohibited by
law to drive while intoxicated or under the influence of drugs.
WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and operating
conditions, and your experience.
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.

14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator fall through
the ice.
HOW TO AVOID THE HAZARD
Never operate the vehicle on a frozen body of water.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your vehicle before each use to make sure it's in safe
operating condition.
Always follow the inspection and maintenance procedures and schedules
described in the Owner's Manual.
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
You may come upon hidden rocks, bumps, or holes suddenly, without
enough time to react.

15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver's license should operate this vehicle.
Even though a child may be within the age group for which some vehicles are
recommended, he or she may not have the skills, abilities, or judgment
needed to operate the vehicle safely and may be involved in a serious
accident.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or uneven tire
pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for this vehicle.
Always maintain proper tire pressure as specified for this vehicle.

16
SAFETY
Operator Safety
WARNING
Operating a damaged vehicle can result in an accident with serious injury or
death. After any overturn or accident, have a qualified service technician
inspect the entire machine for possible damage, including (but not limited to)
brakes, throttle and steering systems.
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the
exhaust system. Use caution when traveling through tall grass, especially dry
grass.

17
SAFETY
Fuel Safety
WARNING
Fuel is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling fuel.
Always stop the engine when refueling.
Always refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the refueling area or
where fuel is stored.
Do not over fill the tank. Do not fill the tank neck.
If fuel spills on your skin or clothing, immediately wash it off with soap and
water and change clothing.
Never start the engine or let it run in an enclosed area. Engine exhaust fumes
are poisonous and can cause loss of consciousness and death in a short
time.

18
FEATURES AND CONTROLS
Component Locations
Cab
Frame
Steering
Wheel
Seat
Belts
Battery
(behind panel)
Seat
Run-Flat
Tires
Front
Platform
Front Bumper/Brush Guard
Winch
Dash Panel
Headlights
Storage Box
(under seat)