Polaris 800 EFI Offroad Vehicle User Manual


 
80
MAINTENANCE
Brakes
Park Brake Adjustment
Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100
hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may
cause “BRAKE” to display in the rider information center, along with activation of the
limiting feature. If this occurs, move the park brake lever to the forward-most position, then
inspect and adjust park brake cable tension.
Tip: If performing this service is difficult due to conditions or location, open the hood and temporarily
disconnect the park brake connector. This will inactivate the limiting function. Reconnect the
connector as soon as possible, and adjust the park brake cable to proper tension.
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Loosen or tighten the nuts on the lever end of the park brake cable as needed.
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at the intervals
outlined in the Periodic Maintenance Chart beginning on page 59.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right. There should be 0.8"-1.0" (20-25 mm) of
freeplay.
3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy,"
have the steering system inspected by an authorized POLARIS dealer.
Suspension Adjustments
The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.
1. Remove the top shock mounting bolts from the inside mounting holes.
2. Reposition the shocks to the outside mounting holes.
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).
Spring Adjustment
Adjust the front and rear shock
absorber springs by rotating
the adjustment cam either
clockwise or counterclockwise
to increase or decrease spring
tension.
Outside Mounting Holes
Inside Mounting Holes
Cam
Rear Suspension Shown
Adjustment is similar for Front Suspension