Sun Coast Cycle Sports carries inspected used parts for the 2004-2014 Polaris Sportsman 800, the first twin-cylinder performance ATV in the Sportsman lineup. The Sportsman 800 paired a 760cc liquid-cooled twin-cylinder engine with Polaris's proven independent rear suspension and On-Demand AWD system, offering a significant power upgrade over the single-cylinder 500 and 600 models. Available in base, EFI, 6x6, and Big Boss configurations, the 800 served as Polaris's premium utility ATV before the Sportsman 850 took over. Our Florida technicians disassemble each Sportsman 800 donor, photograph every component under a unique SKU, and ship free across the continental United States.
Sportsman 800 generation and parts compatibility
| Era | Years | Engine | Key Variants |
|---|
| Early | 2004-2007 | 760cc liquid-cooled twin-cylinder, EFI | Base, EFI, 6x6 |
| Late | 2008-2014 | 760cc liquid-cooled twin-cylinder, EFI | Base EFI, Big Boss 6x6, Forest edition |
The Sportsman 800's 760cc twin-cylinder engine was a new powerplant for the Sportsman line, offering substantially more power and smoother delivery than the single-cylinder 500 and 600. The twin-cylinder architecture provides better balance and less vibration than the single, making the 800 more comfortable on longer rides. Engine internals are consistent across the 800's production run, with incremental improvements to fuel injection calibration and emissions compliance.
The Sportsman 800 shares many chassis components with the Sportsman 700 (2003-2007), including frame dimensions, body panels, racks, and suspension hardware. When the 700 was discontinued, the 800 became the primary twin-cylinder Sportsman. The Sportsman 850, which replaced the 800 starting in 2009, uses a larger 850cc version of the twin-cylinder engine in an updated chassis. Some chassis components interchange between the 800 and early 850 models, but the engine displacement and many mounting points differ.
The Big Boss 6x6 variant adds a powered rear trailer section with its own drive shaft, independent suspension, and a large dump bed. The 6x6's rear axle assembly, trailer frame, and dump bed are unique to that variant and do not interchange with standard four-wheel Sportsman models.
Common Sportsman 800 failure points and replacement parts
Drive belt wear: The twin-cylinder 800's higher power output places increased stress on the PVT drive belt compared to single-cylinder Sportsman models. Belt inspection should be more frequent, particularly when towing or hauling heavy loads. Slipping under load, reduced acceleration, and burning odor are signs of belt wear.
Voltage regulator and stator failure: The 800's higher electrical demands (EFI system, AWD engagement, optional winch and lighting) can stress the charging system. Voltage regulator/rectifier and stator failures cause overcharging, undercharging, or complete electrical failure. Periodic testing of charging system output during service is recommended.
Front differential seal leaks: The On-Demand AWD front differential can develop seal leaks that allow gear oil to escape. Regular differential fluid level checks and prompt seal replacement when leaks are detected prevent internal gear damage.
Throttle body and EFI maintenance: The twin-cylinder engine's EFI system requires periodic throttle body synchronization and cleaning, particularly on ATVs used in dusty conditions. Uneven cylinder fueling causes rough idle and poor throttle response.
Cooling system fan relay failure: The radiator cooling fan relay can fail, preventing the fan from engaging at operating temperature. Overheating in low-speed or stationary operation is the result. Relay replacement is a straightforward electrical repair.
Commonly replaced Sportsman 800 parts
- PVT drive belt (higher wear rate than single-cylinder models)
- Voltage regulator/rectifier and stator
- Front differential seals and fluid
- CV boots and axle shafts
- Cooling fan relay
- Throttle body assembly and fuel injectors
- Plastic body panels and fender flares
- Starter motor and solenoid
- Brake pads and rotors
Frequently asked questions
Q: Will Sportsman 850 parts fit my Sportsman 800?
Some chassis components (body panels, racks, suspension hardware) may interchange between the 800 and early 850 models, but verify by part number. The engines differ in displacement (760cc vs 850cc), so engine internals do NOT interchange. The 850 also received progressive chassis updates that diverge from the 800's platform over time. For body panels and accessories, same-year compatibility is more reliable than cross-generation swaps.
Q: Does the Sportsman 800 share parts with the Sportsman 700?
Yes, for many chassis components. The 800 and 700 share frame dimensions, body panels, suspension hardware, brakes, and most accessories from overlapping production years (2004-2007). The engines are different (760cc twin vs 683cc twin), so engine parts do not cross over. The 700 is a useful donor source for 800 chassis and body components.
Q: What is the Big Boss 6x6 and does it share parts with the standard 800?
The Big Boss 6x6 is a six-wheel-drive Sportsman 800 with a powered rear trailer featuring independent suspension and a dump bed. The front half of the 6x6 (engine, front chassis, cab, controls) is shared with the standard Sportsman 800. The rear trailer assembly, additional drive shaft, rear axle, and dump bed are unique to the 6x6 variant.
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