Polaris Sportsman 9922242 manual

P antone 426C Owner's Manual for Maintenance and Safet y Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. Spor tsman 300[...]

A card containi ng important A T V safety info rmation shou ld be attached to the owner's man ual on the next page. If you cannot locate th is card, or if it has been remove d, please call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth[...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without pr oper training or instruction. S at speeds too fast for your skills or the conditions. S on public r oads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of losing control. AL[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® W e believe Polaris sets a standard of excellence for[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered trademark s of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some minor discr[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potential persona l injury hazard. W ARNING A W ARNING indicates a hazardou[...]

5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuve[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and matin g it with one of yo ur existing keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available [...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the chan ce of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See the OPERA TION section of the owner ’ s manual fo r proper operating procedures. Operating[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme cautio n whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- eli[...]

12 SAFETY Safety W arnings Protective App arel Riding this vehicle without wearing an approved helmet and protective eyewe ar increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield). Using Alcohol or Drugs Operati[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on p avement. A TV tires are design ed for off-road use. If it's una[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to contro l the vehicle o r cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Nev[...]

15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as describ ed in the owne r's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 51. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. • Apply the brakes. • Lock the parking brake when fully stopped. ?[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose te rrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain. Always u se extra caution on rough, slippery or loose terrain. [...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow prope r operating procedures as outlined in this manual. See page 55. Before shifting into reverse gear , always check for obstacles or people behind the A TV . W hen it's safe to proc[...]

19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obst acles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper ope rating proce dures as outlin ed [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load cap acity for this A TV . • Cargo should b e properly di stributed and secu rely attached. • Reduce speed when carrying carg[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A TV can result in a n accident. After any overturn or accident, have a qual ified service dealer insp ect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active veh icl[...]

22 SAFETY Safety Labels and Locations W arning labels hav e been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the la bels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or grap[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 de grees 25 ° . T o prevent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S tee ring becomes difficult. T o prevent loss of c[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death.[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you a re under the age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. 7175374 Rack W a rning, Front and Rear W ARNING • DO NOT TO W FROM RACK OR BUMPER. V ehicle dama ge or tipover may result causing seve[...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse sp eed limiter system. T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, wh ich may result in se ri[...]

27 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lig h ts on and of f. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. All Wheel Drive Switch See page 36 for all wheel drive information. Throttle Lever Operating an A TV wi th sticking or imp[...]

28 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before ope rating the vehicle. Squeeze the brake lever toward the handlebar to ap ply the front and rea[...]

29 FEA TURES AND CONTROLS Parking Brake Locking the P ark ing Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lo ck, squeeze and release the brake lever [...]

30 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , w hich could result in seri ous injury or death. Never ba ck down a hill. Use caution when applying the auxili ary brake. Do not ag gressively apply the auxiliary brake when going forward. The rear wheels may s[...]

31 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may ca use brake drag or b rake lock-up, which co uld result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygro scopic, meaning it rapidly absorbs moisture from the air . The moist[...]

32 FEA TURES AND CONTROLS Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder . Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handleba rs are straight. 2. V iew the fluid level through the indicat or win- [...]

33 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 44 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Always refuel with the engine stopped, and outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel t[...]

34 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is idl ing, move the lever to the desired gear . NOTICE: Shifting gears with the engine speed above idle or while th[...]

35 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engin e, use the rec oil starter . Follow the starting procedures on page 44, c ranking the engine with the recoil starter instead of the main key switc h. 1. Grasp the recoil starte r rope handle tightly . 2. Pull slowly so you can feel the engine strokes. Tip : The [...]

36 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wheel Dr ive s ystem is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD, the demand drive u[...]

37 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in mile s as well as hours of operation. It also includes a reverse speed limiter function that limits the A TV's speed to approximately 7-9 mph (1 1-14 km[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2. Engine Hour Display Indicator 3. Speedometer 4[...]

39 OPERA TION Failure to operate the A TV properly can result in a collision, loss of co ntrol, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new Polaris A TV is the first ten hours of [...]

40 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 67. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area t [...]

41 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a passenger on this A TV . 4. Engine ex haust[...]

42 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you r ide. Find out where the d e signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials. Help kee[...]

43 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 28 76 Brake fluid Ensure pr[...]

44 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit [...]

45 OPERA TION S t arting the Engine 9. T u rn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. NOTICE: Operating the vehicle immediate ly af ter starting could cause engine damage. Allow the engine to warm up for several minutes before operat[...]

46 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e foo trests and both hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determine your path of travel. 6. Release the parking brake. 7. Slow[...]

47 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction sl ightly . T o turn, steer in the direction of the turn,[...]

48 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Engage A WD before wheels begin to lose tractio n. NOTICE: Seve[...]

49 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure coul d cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum) . 3. Always check the terrain care fully before ascending an[...]

50 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. S[...]

51 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum) . 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the b rakes too firmly may cause the rear [...]

52 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hi cle, or on the lef[...]

53 OPERA TION Driving Through W ater Y our A TV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures when operating through water: 1. Determine water depths and cu rrent before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void op erating th[...]

54 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamiliar[...]

55 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sh arp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

56 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing ca rgo improperly ca n alter vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these p recautions when hau ling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO[...]

57 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A T V on warning labels and in the specifications section of this manual. Carg o weight sh ould be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce s peed and car go [...]

58 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve of f.[...]

59 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was teste d and qua[...]

60 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

61 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could resu lt in component failure and cause an accid ent, wh ich may resu lt in serious inj ury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subje[...]

62 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calend[...]

63 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) In[...]

64 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspect[...]

65 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W -50 See page 66. Brake Fluid DOT 4 Only See pa[...]

66 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendatio ns for ambient tempera- ture operation[...]

67 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the A TV . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking br ake. 4. S tart the engine. Allow it to idle for 30 seconds. Sto p the engine. 5. Remove the dipstick. W ipe it dry with a clean clo[...]

68 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking br ake. 4. S tart the engine. Allow it t o[...]

69 MAINTENANCE Oil and Filter Change 1 1. Place towels under the oil filter . Using an oil filter wrench, turn the filter counter-clockwi se to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 14. Install the new oil filter . Aft er the filter contacts t[...]

70 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 60. Maintain the oil level at the bottom of the fill pl ug hole. See page 109 for the part numbers of Polaris products. The fill plug is located on the left si de of the A TV , under the rear f[...]

71 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill. 7. Reinstall the fill plug. T orque to specification. See page 70 for reco m- mendations.[...]

72 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan u nder the gearcase. 6. Remove the drain plug. Use a 15 mm wrench. 7. Allow the oil to drain completely . 8. Clean and reinstall the[...]

73 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 60. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper opera tion of compo- nents. See page 109 fo r the part number[...]

74 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recomme nded oil as needed to bring the level to the bottom of the fill hole threads. 7. Rei[...]

75 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use an 1 1 mm wrench. 7. Allow the oil to drain completely [...]

76 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

77 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attemp t to adjust tie rod alignment. All tie rod adjustments should be perfor[...]

78 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be check ed periodically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the v ehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the top of the side panel and pull it outward to remove it. Footwell Re[...]

79 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and cou ld cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle. Alway[...]

80 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Loosen the wheel nuts slightly . W ARNING! Do not se rvice axle nuts that have a cotter pin installed. See your Polaris deale r . 5. Place a suitable stand under the footrest frame to raise the wheel s[...]

81 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the veh icle to the ground. 4. T orque the wheel nuts to specification. W ARNING! Loose nuts could cause a tire [...]

82 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Remove the seat. 5. Release the air box cover clip s, and remove the air box cover . 6. Remove the air filter . 7. Remove the sleeve from the filter . 8. W ash the sleeve in soapy wate r , the n ri[...]

83 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock the parking br ake. 4. Measure t[...]

84 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a ha logen lamp, don't[...]

85 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the h ousing before storing the v ehicle. Make sure the hou s- ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear . 2. Lock the parking br ake. 3. S top the engine. 4. Remove the drain screw o[...]

86 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifications section begi nning on page 1 14 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S [...]

87 MAINTENANCE Spar k P l u g s S p ark Plug Inspection 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify that the gap is at specification before installation. 5. Reverse the procedure for spark plug installation. T orque to specification. S p ark Plug Condition Normal Spar k Plug The normal insulator tip [...]

88 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, major en gine damage can resu lt if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A T V to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out of the wa[...]

89 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the a rea. We ar eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purgi ng. [...]

90 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balan[...]

91 MAINTENANCE P VT System P VT Drying There m ay be some instanc es when water is accidently ingested into the PVT system. Use the following instructions to dry it out befo re operating. 1. Move the vehicle out of the water . 2. Remove the P VT drain plug. Use a 17 mm w rench, a f lat screw- driver , or the spark plug wrenc h. 3. Allow the water t[...]

92 MAINTENANCE Battery Improperly connecting or discon necting battery cables can result in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains su[...]

93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking br ake. 3. Open the front cover . 4. Disconnect the battery hold-down strap. 5. On conventional batteries, remove the ba ttery vent tube. 6. Disconnect the black (negative) battery cable first. 7. Disconnect the red (positive) battery cable last. 8. Lift [...]

94 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructions on page 96 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batte ry in t[...]

95 MAINTENANCE Battery Batter y S torage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recharge as needed to maintain a full charge. Polaris recomm[...]

96 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during charging. See page 9 3. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.27[...]

97 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100[...]

98 MAINTENANCE Cleaning and S torage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pre ssure may damage co mponents. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, incl[...]

99 MAINTENANCE Cleaning and S torage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearin gs • T ransmission seals •B r a k e s ?[...]

100 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C l[...]

101 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage coul d occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as rec ommended. See page 98. Stabilize[...]

102 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the fluid levels. Chan ge fluids as recomm ended in the Period ic Maintenance Chart beg inning on page 60. • Demand drive unit (front gearcase) • T ra nsmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1[...]

103 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 60. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV w[...]

104 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. T urn the fuel valve of f. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to preven t loss during transporting. 7. Always tie the frame of the A TV to [...]

105 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. S pring Adjustment s The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counter -clockwise to increase or decre ase spring tension. Alwa ys ad just both sides equally . Accessory springs are available through your Polaris dea l[...]

106 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adj ustment of the handleba rs or inco rrect torquing of the adjuster block tightenin g bolts can caus e limited steering or loo sening of the handlebars, resulti ng in loss of control and serious injury or death. Follow the adjustment procedures exac[...]

107 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrate d at the factory for optim al performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Ab ove 6000 feet (1800 m) th e engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea[...]

108 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16" [...]

109 POL ARIS PRODUCTS Pa r t Number Desc ription Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol ) 2876244 PS-4 PLUS P erformance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Synth etic 2W -50 4-Cycle Oil (gal.) Gearcase / T ra nsmission Lubrican ts 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AG[...]

110 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range (if equipped). Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 52). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range[...]

111 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S t art Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solu[...]

112 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Solut[...]

113 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace wi th new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Foule[...]

114 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC Sportsman 300 Maximum W eigh t Capacity 385 lbs. (175 kg) (includes weight of operator , cargo and accessories) Dry W eight 550 lbs. (250 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 20.3 oz. (600 ml) Demand Drive Flui d 5 oz. (148 ml) Front Rack Capaci[...]

115 SPECIFICA TIONS Jetting Chart Clutching Ch art Sportsman 300 Drive Ratio, Fron t 3 .6:1 Drive Ratio, Final 15.18:1 T ires/Pressure, S tandard models Front 22x7-12 / 5 psi (34.5 KPa) Rear 22x10-12 / 5 psi (34.5 KPa) T ires/Pressure, LE models Fr ont 23x7-12 / 5 psi (34.5 KPa) Rear 23x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut wit[...]

116 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

117 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty c[...]

118 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIE S AND REMEDIES The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse o r improper handling. This warranty also does not cover any A T[...]

119 W ARRANTY LIMIT A TIONS OF W ARRANTIE S AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensat i[...]

120 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR T HER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not allow limi- tations on h[...]

121 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that hav e received authorization for export from Polaris Industries. Deal[...]

122 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

123 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warrant y is in additi on to the Polaris sta ndard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.S. Environ[...]

124 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY AR E THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH OF[...]

125 MAINTENANCE L OG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

126 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

127 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 103 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 82 All Wheel Drive Swi tch . . . . . . . 27, 36 All Whe el Drive System . . . . . . . . . . 36 Apparel, P rotective . . . . . . . . . . . . . 12 B Battery . . . . . . . . . . . . . . . . . . . . 92-97 Charging (Conventional) . .[...]

128 INDEX H Handlebar Adjust ment . . . . . . . . . . 106 Hauling Cargo . . . . . . . . . . . . . . . 56-57 Headlamp Replac ement . . . . . . . . . . 84 Headlight Beam Adjust ment . . . . . . 83 Headlight S witch . . . . . . . . . . . . . . . 27 Helmet . . . . . . . . . . . . . . . . . . . . . . . . 8 I Idle RPM Adju stment . . . . . . . . . . 107 [...]

129 INDEX S Storage . . . . . . . . . . . . . . . . . . . 98-103 Switches AWD Switch . . . . . . . . . . . . 27, 36 Engine Stop Switch . . . . . . . . . . 26 Headlight Swit ch. . . . . . . . . . . . 27 Main Key Swi tch . . . . . . . . . . . 26 Mode/Reverse Ove rride Switch 26 T Taillight . . . . . . . . . . . . . . . . . . . . . . . 84 Throttle Cab[...]