How to Change Oil Polaris Sportsman 800

In this article we'll explain how to change oil and filter on a 2005-2014 Sportsman 800.  This process is straight forward and expect no surprises.  Before getting started have the following tools and supplies on hand.

- 2 qts. oil, 0w-40 or your choice
- Oil Filter, Wix 51356
- T40 Torx Bit
- catch pan
- funnel

Begin the process by warming the engine up to operating temperature and parking on level ground.  Next remove the oil drain plug, T-40 Torx bit.  While the oil drains remove the spin off oil filter located on front of the engine.  With the oil drained reinstall the drain plug and oil filter.  The process is completed by adding two quarts of oil through the dip stick tube.  Remember to recheck the oil level after idling the Sportsman 800 for a minute or so.  Performing a oil on an ATV doesn't get any easier than on the Sportsman. Everything ATV UTV Reviews

Polaris Sportsman 800 BELT CHANGE

The Sportsman 800 throws power to the ground through a CVT Belt setup.  Replacing the belt on the Sportsman is part of routine maintenance and belts do wear out over time.  If your belt is squealing or you notice a loss in performance it's probably time for a belt change.   Recently we had the opportunity take a look at the CVT or PVT (Polaris Variable Transmission) setup and change the belt on a 2012 Sportsman 800.  In this article we'll explain how to change the belt, but first here is what tools you'll need.    WATCH HOW TO VIDEO

1. To remove foot well: T25 Torx Bit, 10mm wrench
2. To remove belt cover: 10mm socket, extension, ratchet
3. To remove belt: 16mm socket, impact wrench, primary clutch puller

Begin by removing the foot well, secured by four T25 Torx screws and four plastic rivets.  You may have to pull upward slightly on the front and rear fender to completely release it.  Next you'll need to remove two plastic rivets located under the seat (see picture or watch video).  Removing these two plastic rivets will allow you to pull the plastic up and access the two clamps securing the rubber boot.  After loosening the clamps remove the eight 10mm bolts securing the PVT belt cover.  Next work the cover off by pulling outward and wiggling it at the same time.  Now that the cover is off you can see the PVT setup consisting of the primary clutch, secondary clutch and belt.  The primary clutch will need to be removed to gain enough slack to remove the belt.  There are other methods for removing the belt, but we have found this one to work best for us.  Next remove the 16mm bolt securing the primary clutch, it is standard threads, so counter clockwise removes it.  Next screw the primary clutch puller into the center of the primary clutch and tighten with a impact wrench.  It should pop off rather easily using this method.  Now that the primary clutch has been pulled remove the belt and take notice of the orientation.  Next reinstall the new belt and primary clutch.  Once the 16mm bolt has been reinstalled and tightened check the PVT belt cover seal.  The PVT cover seal needs to be removed and cleaned if dirty to ensure a water tight seal.  Once completed everything can be reassembled!

Polaris Ranger front Differential Fluid Change: 9.3 oz Fluid Capacity

Changing the front diff fluid on the Ranger 800 is a quick and easy job.  The most difficult part is of the entire job is removing the fill plug on the front of the diff.  The oil change is relatively mess free due to the low 9.3 oz. fluid capacity.  Before getting started make sure to have a 8mm allen wrench and Polaris Demand Drive Hub Fluid or Polaris Angle Drive Fluid on hand.  Lots of discussion out there on using different brands such as Amsoil and fluid variations such as automatic transmission fluid and hydraulic fluid in the front differential gearcase on these Rangers.  You can do you're own research on that, but many swear by these alternatives.
Begin the process by driving the Ranger at road speeds for 15 minutes or more to warm the fluid up making the drain process quicker and more complete.  Next remove the 8mm drain plug with the allen wrench, there is a hole in the front skid plate for access.  As the fluid drains remove the fill plug located on front of the differential, you can do this without removing plastics.  Once fluid is drained reinstall the drain plug.  To fill you can attach a hose to the top of the Polaris Demand Drive Hub Fluid or Angle Drive Fluid nozzle and plumb it into the fill hole or use a funnel with hose, just be creative.  Others have filled the front diff by pouring fluid down the vent hose under the hood.  I've attached the video of our fluid change, but to be honest it was early on and not the best.