Polaris Sportsman 9920364 manual

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A card containi ng important A TV safety informa tion should be attached to the owner's man ual on the next page. If you canno t locate th is card, or if it has been removed, plea se call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive[...]

1 WELCOME Thank you for purch asin g a Polaris vehicl e, 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 a l[...]

2 POLARIS and POLARIS THE W A Y OUT are regist ered tradem arks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication. Due to constant improvements in the design and quality of production compo nents, some minor discre[...]

3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Emission Control Systems . . . . . . . . . . . . . [...]

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5 KNOW Y O UR VEHICLE As the operator of the vehicle, yo u are responsible for your personal safety , the safety of others, an d the prot ection of our en vironmen t. Read and understand your o wner's manual, which includes valuable informa- tion abou t all aspects of your vehicle, includi ng safe operating proce- dures. V ehicle Identificatio[...]

6 SAFETY Safety Decals and Locations W arning decals have been placed o n the A TV for your protection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manu al dif fer from the decals on your A TV , always read and follow the instruc tions of the decals on the A TV . If any decal becomes[...]

7 SAFETY Safety Decals and Locations Discretionary W arning WARNING • Never operate this A TV on HILLS steeper than 25 degree s 25 ° . To p r e - vent flip-over on hilly te rrain, when going up or down, use throttle and brakes gradually . • REVERSE operation can be dangerous even at lo w speeds. Steering becomes difficul t. T o prevent flipove[...]

8 SAFETY Safety Decals and Locations “No P asseng er” W arning WARNING NEVER ride as a passenger . P assengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. Age 16 W arning WARNING Operating this A TV if you are under th e age of 1 6 increase s your chance of severe injury or d eath. NEVER operate this A TV if you are under[...]

9 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. T o pr event serious injury , do not operate vehicle with gu ard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in seriou s injury o[...]

10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the ch ance of injury . Helmet W ea ring 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 t[...]

11 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 Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WA R N I NG F ailure to follow the warnings contained in this manual can result in severe injury or death. A Po laris A TV is not a toy and can be hazardo us to operate. T his vehicle handles differently th[...]

13 SAFETY Operator Safety Safety T raining A TV safety training is a top priority for Polaris. Wh en you p urch ased your new A TV , your deal er instructed you o n the autho rized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you [...]

14 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The sa fety alert symb ol , on your vehicle or in this manual, alerts you to the potential for in ju[...]

15 SAFETY Operator Safety • Read this manual and all labels carefully , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV RiderCourse sm . Conta ct A TV Enrollment Express a[...]

16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as de scribed in this manual. Practice turning at low speeds befo re attempting t[...]

17 SAFETY Operator Safety • 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 proper procedu res when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. On slip pery surfaces like ice, travel slowly[...]

18 SAFETY Operator Safety FOR MORE INFO RMA T ION ABOUT A TV SAFETY , call the Consumer Product Sa fety Commission at 1- 800-638-2 772, or visit www .cpsc.gov , visit www .atvsafety .org, or call P olaris at 1-800-342- 3764. Equipment Modifications W e are concerned for the safety of our customers and for the general public. Therefore, we strongly [...]

19 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV without proper instruction. WHA T CAN HAPPEN The risk of an accident is greatl y increased if the operator does n ot know how to operate the A TV properly in different situ ations and on different types of terra in. HOW TO A VOID THE HAZARD Beginning and inexperi enced opera[...]

20 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Carrying a pa ssenger on an A T V . WHA T CAN HAPPEN Carrying a passeng er greatly reduces the operator's ability to balance and control the A TV , which could cause an accident and injury to the operator and/or passenger . HOW TO A VOID THE HAZARD Never carry a passeng er . The purpose of[...]

21 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV on p ublic streets, roa ds or highways. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public street, road or highway , including dirt and gravel roads. In many states it's illegal to operate A T Vs o[...]

22 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating the A TV after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator jud gment. Reaction time may be slower and operator bala nce and perception could be affe cted. Consuming alcohol and/or drugs before or while operating an A[...]

23 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increa ses the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt wheelies, ju mps, or other stunts. Avoid exhibition driving. WA R N I NG POTENTIAL HAZARD F ailure to inspec t the [...]

24 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejecti on from the A TV . If the operator's foot is not firmly planted on the footres[...]

25 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD F ailure to use extra caution whe n operating on exce ssively rough , slippery or loose terrain. WHA T CAN HAPPEN Operating on e xcessively roug h, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO A VOID THE HAZARD [...]

26 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating on e xcessively ste ep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. N ever operate th e A TV on hills steeper than 25 degrees. WA R N I NG POTENTIAL HAZARD Climbing hills improperly . WH[...]

27 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD T raveling dow nhill improperly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures fo r traveling down hills as describe d in the owner's manual . NOTE: A special technique is required whe n brak[...]

28 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Stalling, rolling backwards or improp erly dismounting while climbi ng a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill . If your A TV is equipped with Active Descent Control, always enga ge AWD before ascending a hill. See[...]

29 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Improperly operating over obstacl es. WHA T CAN HAPPEN Operati ng over obst acles coul d cause loss of control or over turn. HOW TO A VOID THE HAZARD Before operating in a ne w area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen tre es when possible. If unav[...]

30 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating the A TV through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of tracti on and loss of control, which co uld lead to an accident o r overtu rn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowing water . If it's unavoidabl[...]

31 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV with improper tire s, or with improper or uneven tire pressure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO A VOID THE HAZARD Always use the size and type of tires spe[...]

32 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading a nd towing can cause cha nge s i n vehicle handl ing, which could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A TV . Cargo should b e prop[...]

33 SAFETY Operator Safety WA R N I NG Operating a da maged A TV can result in an accident w ith seri ous injury o r death. Afte r any overtu rn or accident , have a qualified se rvice dealer inspect the entire ma chine for possibl e damage, includin g (but not limite d to) brakes, throttle and st eering systems. WA R N I NG Safe operation of this r[...]

34 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse speed limi ter syst em .T o gain additional power while backing, depress the override switch. NOTE: The override sw itch also allows acti vation of All Whe el Drive in reverse, if the AWD switch is on. This switch is also used to toggle through[...]

35 FEA T URES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the e ngine quic kly . The engine will not start o r run whe n the switch is of f. NOTE: Both th e main switch an d the engine stop switch will shut o ff all electri- cal power to the vehi cle, inclu ding li ghts. Main K ey S[...]

36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are contro lled by pressin g the throttle lever . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This A TV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck t[...]

37 FEA T URES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to ap ply the front and rear brakes. These brakes are hydraulically activ ated disc type brake s that are activat ed by on ly one lever . Always test brake lever travel and master cylinder fluid level befo re riding. When squeezed, the lever should feel firm. Any sp[...]

38 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can b e seen through an indicator window on the top of the master cylinder . This eye will appear dark wh en the fluid level is full. When fluid is low , the eye will be clear . NOTE: When che cking the fluid level,[...]

39 FEA T URES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in PA R K . 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 b[...]

40 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brak e system is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. NOTE: Since this is a rear brake only , it will not be as effective as the all-wheel single lever system. The auxili ary foot b rake is loc ated on the[...]

41 FEA T URES AND CONTROLS Fu e l T a n k C a p Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane numb er of 87=(R + M/2) octane. Do not use E-85 fuel . F uel Filter The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the f[...]

42 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the v ehic le. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the A TV is left unattended, always place the transmission in P ARK and lock the parking brake. Belt Life T o extend belt life, use low forward [...]

43 FEA T URES AND CONTROLS Recoil Starter If the battery is too weak to start the engin e, use th e recoil s tarter . Follow the starting procedures on page 57, c ranking th e 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. NOTE: Th[...]

44 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 W D indicator light in the instrument cluster will be on. When in A W D, the demand drive[...]

45 FEA T URES AND CONTROLS Active Descent Cont rol (ADC) System The ADC sy stem (if equip ped) a llows engi ne braking to all four wheels when the vehicle descends a hill or incline. If your A TV is equipped with Active Descent Control, always engage A WD before ascending or descending a hill. Engaging Active Descent Control The ADC system will aut[...]

46 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. Th e inst rument clu ster measur es dis- tance in miles 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. Refe[...]

47 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2. 5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over -voltage may have occurr ed and the i nstrument cl uster may have shut off to protec[...]

48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ugh the mo de options. The reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odom eter record s the mile s travel ed by the A TV . [...]

49 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. Any move - ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn th[...]

50 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Screen The gauge indicates wheth er or not current is flowing through the A WD coil (only on models with switch[...]

51 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Pr ogrammable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the se rvic e interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Ce[...]

52 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only . Please see your Polaris de aler fo r all major repairs. See page 53 for Blink Codes and Failu re Descriptions. Use the follow- ing procedure to do wn load blink codes (failure codes) from the EFI modul[...]

53 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Descripti on 12 BEGIN SEQUENCE 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Senso r High 41 Air T emp Sensor Low V oltage 41 Air T emp Sensor High V oltage 42 Engine Coolant T emp Low V[...]

54 OPERA TION F uel Safety WA R N I NG Gasoline is highly flammab le and explosive under certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdo ors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area whe re refueling is[...]

55 OPERA T ION Break-In P eriod The break-in period for your new Polaris A TV is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as foll owing the proce- dures for a proper break-in. Careful treatment of a new engine and drive components will result i[...]

56 OPERA TION Pre-Ride Checklist WA R N I NG If a proper inspection is not done befor e ea ch use, severe injury or death could result. Always in spect the vehicl e before each use to ensure it's in proper operating co ndition. Item Remarks P age Brake system/lever travel Ensure proper operation 37 90 Brake fluid Ensure proper level 38 Auxilia[...]

57 OPERA T ION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. NOTE: The starte r interl ock will prevent the engine from starting if the trans- mission is in gear and th e brake is not engaged. 4. Sit on the vehicle and move the engine stop switch to RUN. NOTE: Do not [...]

58 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load di stribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi - cations section of the owner's manual and on the safety decals. Car go weight shou ld be evenly dist[...]

59 OPERA T ION Hauling Cargo WA R N I NG Overloading the vehi cle or carrying or towing cargo improperly can alte r vehicle handli ng and may ca use loss of c ontrol or brake instability , which can result in serious injury or death. Always follow these precaution s when hauling carg o: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN H[...]

60 OPERA TION Driving Safely Driving Procedures 1. W ear protective ridin g ge ar . See page 10. 2. Sit upright with both feet on th e foo trests and both hand s 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 determi ne your path of travel. 6. Release the parkin[...]

61 OPERA T ION Driving Safely 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 slightly . T o turn, steer in the directi[...]

62 OPERA TION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather , follow these precautions: 1. Slow down wh en enter- ing slippery areas. 2. Engage A WD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and av[...]

63 OPERA T ION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. If your A TV is equipp ed with Active Descent Control, always engage A WD before ascending a hill. See page 45. 2. Drive straight uphill. 3. A voi d steep hills (25 ° maximum) . 4. Keep both feet on the footrests . 5. Shift your weight uphill. 6. P[...]

64 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can be dangerou s and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill. 3. Keep your feet on the footrests . 4. S teer slightly into the hill to maintai[...]

65 OPERA T ION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. If your A TV is equipp ed with Active Descent Control, always engage A WD before descend ing a hill. See page 45. 2. Shift your weight uphill. 3. Drive straight downhill. 4. Slow down. 5. Squeeze the brake lever gradually . NOTE: Before operatin g you[...]

66 OPERA TION Driving Safely 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 b ody weight uphill. 2. If your A TV is equipp ed with Active Des cen t Control, engage A WD. See page 45. 3. Leave the transmis[...]

67 OPERA T ION Driving Safely Driving Through W ater Y our A TV can operate th rough water with a maximum recom- mended dep t h eq ual to the bot- tom of the footrests. Follow these procedures when operat- ing throug h water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks hav e g radual inclines. 3. Pro[...]

68 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for ha zards such as logs, rocks and low hanging branches. WA R N I NG Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacle s are immediately visi[...]

69 OPERA T ION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the veh i cle. 2. Always avoid bac kin g downhill . 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . NOTE: Y our Polari[...]

70 OPERA TION Driving Safely P arking on an Incline A voi d parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Always block the rear wh eels on the downhil l side.[...]

71 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 spa rk arrestor that was tested and qu[...]

72 MAINTENANCE P e riodic Maintena nce 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 in tenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals [...]

73 MAINTENANCE P e riodic Maintena nce Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions.) Q Have an authorized Polaris dealer perform these services. WA R N I NG Imp[...]

74 MAINTENANCE P e riodic Maintena nce 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 Cal[...]

75 MAINTENANCE P e riodic Maintena nce 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. Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary E Throttle Body Intake Duct 50 H 6 M[...]

76 MAINTENANCE P e riodic Maintena nce 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) Insp[...]

77 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 72. Items not listed in the chart should be lubr icated at the General Lubrication interval. NOTE: The a-arms and lower co ntrol arms are lubricated at the facto ry , and no additional lub rication will [...]

78 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Pola ris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil desi gned to provide the ultimate in lubrication performance and pro tection. See page 12 7 for the part num- bers of Po[...]

79 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the A TV . NOTE: A rising oil level between checks in cool weather driving can indica te contaminan ts such as gas or mois ture col- lecting i n the cr ankcase. If the oil level i s over the full/safe mark, change the oil immedi- ately . 1. Position the [...]

80 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 72. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. S tart the engine. All ow it to idle for two to three minutes. 3. S top the engine. 4. Clean the [...]

81 MAINTENANCE Oil and Filter Change 12. Place shop towels beneath the oil filter . Using an oil filter wrench, turn the filter coun terclockwise to remove it. 13. Using a clean dry cloth , clean the filter sealing surface on the crank- case. 14. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring i[...]

82 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must b e performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure[...]

83 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 72. Maintain the oil level at the bottom of the fill pl ug hole threads. W e recommend the use of Polaris Premium AGL Synthetic Gearca se Lubricant. See page 127 for the part numbers of Polaris[...]

84 MAINTENANCE T ransmission Oil Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain com- pletely . 4. Clean and reinstall the drain plug. T orque to 22 ft. lbs. (30 Nm). 5. Add 32 oz. (9 48 ml) of the recomm en ded oil. 6. Reinstall the fill plug. T orque to 22 ft. lbs. (30 [...]

85 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level su rface. Remove t he fill plug. Check the fluid level. 2. Add the recomme nded dem and driv e fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. T orque to 8-10 ft. lbs. (1 1-14 Nm). Fluid Change 1.[...]

86 MAINTENANCE Active Descent Control (ADC) Fluid If your veh icle is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fluid an d ADC fluid). See page 84 for d emand drive fluid maintenance . Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart begin[...]

87 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level su rface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly cl ean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and di[...]

88 MAINTENANCE Cooling System The engin e coolan t level is controlled, or maintai ned, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases , the expa nding (heated) excess coolant is forced out of th[...]

89 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s it s ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recov[...]

90 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handleba r . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s. If the fluid leve l is low and the diaphragm is not extended, a leak is li[...]

91 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. 1. Place the handlebars in a straight-ahead position. 2. Place stands in front of the vehicle, per- pendicular to the rear tires. 3. T ie an elastic string around th e stands[...]

92 MAINTENANCE Steering Assembly The steering assemb ly of the A TV shou ld be check ed p eriodically for loose nuts and bo lts. If loose nuts and bolts are fo und, see your Polaris dealer for service before ope rating the vehicl e. Side P anel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rea r cab. W ith a firm motion, [...]

93 MAINTENANCE Tires Refer to the specifications section beginning on page 1 28 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operati ons. All se[...]

94 MAINTENANCE Tires Wheel Installation 1. Place the transmission in P ARK. 2. Lock the parkin g brake. 3. Place the wheel on the hub with the valve stem toward the out side and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger -tighten them. 5. Lower the veh icle to the grou nd. 6. T orque the wheel[...]

95 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . NOTE: Install a ne[...]

96 MAINTENANCE Lights When servicing a ha logen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Remove the screw fro m the rear of the po d. 3. Li[...]

97 MAINTENANCE Lights High 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 . Place the transmission in P ARK. 2. Measure the distance from the floo r to the cen[...]

98 MAINTENANCE Lights Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedome ter harnesses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a sm[...]

99 MAINTENANCE Lights Lower Headlamp Replacement 1. T urn the back of the headlight harness counterclockwi se and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headla mp. 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harne ss clock- wise to secure th[...]

100 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifi cations sect i on beg inn ing on p age 1 28 for the recom- mended spark plug type and gap fo r your vehicle. T orq ue spark plugs t o specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition aft[...]

101 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spar k Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be fl aky and white. A white insulator t[...]

102 MAINTENANCE V ehicle Immersion 1. If it's impossible to tak e yo ur A TV to a dealer before starting it, fol- low the steps outlined below . 2. Move the A TV to dry land or at the very least, to water below the footrests. 3. Check the air bo x. If water is present, dry the ai r box and replace the filter with a new filter . 4. Remove th e [...]

103 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge acc umulated carbon from the exha ust p i pe/muffler . 1. Remove the arrestor cle an-out plug from the bottom of the muf fler . 2. Place the transmission in PA R K . 3. S tart the engine. 4. Quickly squeeze and release the throttle lever several times to pur ge carbo[...]

104 MAINTENANCE PVT System WA R N I NG F ailure to comply with the instru ctions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failu re may occur at a high speed. The PVT system has been precision ba lanced. Any modification will cause the syst em to [...]

105 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed de[...]

106 MAINTENANCE PVT System When T o Use Low Range and High Range PVT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall the [...]

107 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A sealed battery can be identified by its flat covers on the top of t he battery . A conventional battery has six filler caps on the top of the battery . Conventional Battery Always keep battery terminals and connec[...]

108 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not to tip a conve[...]

109 MAINTENANCE Battery Battery Installation 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 hinde r vehicle performance. Follow the battery charging instructio ns on page 1 1 1 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery [...]

110 MAINTENANCE Battery Battery Storage 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 t orag e and recha r ge as needed to mainta in a full charge. NOTE: Powe[...]

111 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prev ent damage from leak- ing or spilled ele ctrolyte during cha rging. See page 108. 2. Char ge the battery with a char ging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the spec ific grav- ity to [...]

112 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 hours after the end o f charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top o f batter y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None requir[...]

113 MAINTENANCE Cleaning and Storage W ash ing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleanin[...]

114 MAINTENANCE Cleaning and Storage W ashing th e V ehicle If a high pressure water system is u sed for clea ning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void dir ec ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals ?[...]

115 MAINTENANCE Cleaning and Storage 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. NOTE: Chro me wheels exposed to road salt (or salt in the air in coasta l areas) are more su sceptible to corrosion if no t properly cle[...]

116 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 1 1 3. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T r eatment or Polaris Fuel S tabilizer . Follow the instructions on th e container for the recomm en de d amount. NOTE: Ca[...]

117 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the flu id levels. Add or chan ge fluids as recommen ded in the Periodic Maintenance Char t beginni ng on page 7 2. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • T ransmission • Brake fluid (chang[...]

118 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubric ate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 72. Battery Storage See pages 1 10-1 1 1 for storage an d char ging procedures. Storage Area/Covers Set the tire pressure and safely suppor t the A TV [...]

119 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in PA R K . 3. Lock the parkin g brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or ro pe. Do not attach tie straps t[...]

120 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shoc k absorber sp ring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer . Adjuster[...]

121 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four hand lebar bolts. 3. Adjust the handlebar to t he desired heigh t. NOTE: Be sure the handlebars do not contact the gas tank or any other pa rt of the machin e when turned fully to the left or right. 4. T orque the fr[...]

122 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Pola ris dealer for adjustment. Throttle Cable F reeplay 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 an[...]

123 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 66). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a hi gher sp eed or us e low range more freque[...]

124 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F a ils to Start Engine Backfires Possible Cause Solution 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 Solution Out of fuel Refuel,[...]

125 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recomme nded fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plug(s)[...]

126 TROUBLESHOOTING Engine Stops or Loses P ower 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 Insp ect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plug(s) In spect, cl ea n and/o r replace [...]

127 POL ARIS PRODUCTS Pa r t Number Description Engine L ubricant 2870791 F oggin g Oil (12 oz. Aeroso l) 2871281 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oi l (qt./.95 l) 2871844 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oi l (gal./3.8 l) Gearcase / T rans mission Lub ricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 28736[...]

128 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 EFI Gross V ehicle W eight 1200 lbs. (544 kg) Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.7 qts. (2.5 l) Front Rack/S torage Box Capacity 90 lbs. (40.8 kg) Rear Rack/Storage B ox Capacity 180 lbs. (81.6 kg) Receiver Hitch T ongue Capacity [...]

129 SPECIFICA TIONS Clutching (EBS Models) NOTE: *EBS model s require no h elix/spring adjustment Clutching (Standard Models) Sportsman 500 EFI Shift T ype Side Lever (H/L/N/R/P) Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 1 6.30:1 Gear Reduction, Forward 10.49:1 Drive Ratio, Front 3.82:1 T ires/Pressure, Front 26x8-12 / 5 psi T ires/Pressu[...]

130 W A RRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, 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 [...]

131 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris l imited warrant y excludes 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 or improper handling. This warranty also does not cover any A TV[...]

132 W A RRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRA NTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some states do not allow limi- tations o[...]

133 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 LO CA - TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. De[...]

134 W A RRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you ha[...]

135 W ARRANTY U.S.A . EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limit ed warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the[...]

136 MAINTENANCE L O G Present this section of your manual 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 / COMMENTS[...]

137 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

139 INDEX G Gear Selec tor . . . . . . . . . . . . . . . . . . . 42 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 11 H Hand Brake . . . . . . . . . . . . . . . . . . . . 90 Handlebar Adjust ment . . . . . . . . . . 121 Hauling Cargo . . . . . . . . . . . . . . . 58-59 Headlight Housing Replacement . . . 98 Headlight La mp Replaceme nt . . [...]

138 INDEX A Accessories . . . . . . . . . . . . . . . . . . 118 Active Descent Control Fluid . . . 86-87 Active De scent C ontrol Sys tem . . . . 45 ADC System . . . . . . . . . . . . . . . . . . 45 Age Restrictions . . . . . . . . . . . . . . . . 12 Air Filt er . . . . . . . . . . . . . . . . . . . . . 95 All Wheel Drive Syst em . . . . . . . . . [...]

140 INDEX S Spark Arrestor . . . . . . . . . . . . . . . . 103 Spark Plugs Inspection . . . . . . . . . . . . . 100-101 Recommendati ons . . . . . . . . . 100 Torque Specificat ion . . . . . . . 100 Specifications . . . . . . . . . . 128-129 Spring Adjustment, Rear Shock . . 120 Starting th e Engine . . . . . . . . . . . . . 57 Steering As sembly .[...]