Polaris Sportsman 9921161 manual

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 pro duce an exciting 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 OU T are registere d trademarks of Polaris Indus- tries Inc. Copyright 2007 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 discrep[...]

3 T A BLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Emission Control Systems . . . . . . . . . . . . .[...]

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5 KNOW Y OUR VEHICLE As the operator of the vehicle, yo u are responsible for your persona l safety , the safety o f others, and th e prot ection o f our en vironmen t. Read and understand your o wner's manual, which includes valuab le informa- tion abou t all aspects of your vehicle, including safe operating proce- dures. V ehicle Identificat[...]

6 SAFETY Safety Decals and Locations W arning decals have been pl aced on 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 manual dif fer from the decals on yo ur A TV , always read and follow the instruc tions of the decals on the A TV . If any decal become[...]

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 dow n, use throttle and brakes gradually . • REVERSE operation can be dangerous even at lo w speeds. Steering becomes difficul t. T o prevent flipov[...]

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 increases 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 prevent seriou s injury , do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in serious injury or [...]

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 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 th[...]

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 RN I N G 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 hazardous to operate. This vehicle handles differently than[...]

13 SAFETY Operator Safety Safety T raining A TV safety training is a top priority for Polaris. Wh en you p urchased your new A TV , your deal er instructed you o n the authorized A TV RiderCourse sm available to you an d your e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and[...]

14 SAFETY Operator Safety 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 sa fety alert symbol , on your vehicl e or in this manual, alerts you to the potential for in jur[...]

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 eli gible family members are entitled to take the A TV RiderCourse sm . Conta ct A TV Enrollment Express [...]

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 o bstacles as described in this manual. • Always be careful of skidding or sliding. On slip pery surfaces like ice, travel slowl[...]

18 SAFETY Operator Safety FOR MORE INFO RMA TION ABOU T A TV SAFETY , call the Consumer Product Sa fety Commission at 1-80 0-638-2772 , or visit www .cpsc.gov , visit www .atvsafety .org, or call Pola ris 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 RN I N G 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 T V properly in different situ ations and on different types of terra in. HOW TO A VOID THE HAZARD Beginning and inexperi enced oper[...]

20 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Carrying a pa ssenger on an A TV . 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 pu rpose of[...]

21 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Operating this A TV on p ublic streets, roads 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 TVs on [...]

22 SAFETY Operator Safety WA RN I N G 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 RN I N G 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 RN I N G POTENTIAL HAZARD F ailure to inspec t the [...]

24 SAFETY Operator Safety WA RN I N G 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 RN I N G 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 rough, 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 Do[...]

26 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Operating on e xcessively steep hil ls. 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 the A TV on hills steeper than 25 degrees. WA RN I N G POTENTIAL HAZARD Climbing hills improperly . WHA[...]

27 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD T raveling downhil l 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 RN I N G POTENTIAL HAZARD Stalling, rolling backwards or improperly 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 equippe d with Active Descent Control, always enga ge AWD before ascending a hill. See[...]

29 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Improperly operating over obstacl es. WHA T CAN HAPPEN Operati ng over obstac les could ca use loss of control or overturn. 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 unavo[...]

30 SAFETY Operator Safety WA RN I N G 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 overturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowing water . If it's unavoidable[...]

31 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Operating this A TV with improper tires, 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 spec[...]

32 SAFETY Operator Safety WA RN I N G POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading a nd towing can cause change s in vehicle handling, wh ich 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 proper[...]

33 SAFETY Operator Safety WA RN I N G Operating a da maged A T V can result in an accident with se rious injury or death. Afte r any overturn or accid ent, have a qualified service dealer inspect the entire ma chine for possible damage, incl uding (but not limited to) brakes, throttle and st eering systems. WA RN I N G Safe operation of this rider [...]

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

35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the e ngine quickly . The engine will not start or run whe n the switch is of f. NOTE: Both th e main switch and the engine stop switch will shut off all electri- cal power to the vehi cle, inclu ding lig hts. Main K ey Switch[...]

36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are contro lled by pressing 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 th[...]

37 FEA TURES 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 activated by only one lever . Always test brake lever travel and master cylinder fluid level befo re riding. When squeezed, the lever should feel firm. Any spong[...]

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 c king the fl uid leve[...]

39 FEA TURES 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 br[...]

40 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brake s ystem 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 br ake is locate d on the[...]

41 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct ch oke and throttle settings during start- ing. F uel V alve The fuel valve is located on the bottom of the fuel tank. Access the fuel valve through the right front wheel well. OFF: For vehicle storage and when [...]

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 TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engin e, use the recoil starter . Follow the starting procedures on page 55, c ranking the engi ne 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: The r[...]

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 WD indicator light in the instrument cluster will be on. When in A WD, the demand drive u[...]

45 FEA TURES 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 auto[...]

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 cluster m easures d is- 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 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 2. 5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over -voltage may have occurr ed and the in strument cl uster may have shut off to protect[...]

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 rev erse 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 miles traveled by the A TV . T[...]

49 FEA TURES 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. An y move- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the[...]

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 Sc r een The gauge indicates wheth er or not current is flowing through the A WD coil (only on models with swit[...]

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

52 OPERA TION F uel Safety WA RN I N G Gasoline is highly flammable and e xplosive under certain condition s. • Always exercise extreme cautio n whenever handling g asoline. • 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 whe re refueling is [...]

53 OPERA TION 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 gaso line. 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[...]

54 OPERA TION Pre-Ride Checklist WA RN I N G 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[...]

55 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Lock the parking b rake. NOTE: The starte r interlock will prevent the engine from starting if the trans- mission is in gear and th e brake is not engaged. 4. T urn the fuel valve on. 5. Sit on the vehicle. NOTE: Do not use the choke[...]

56 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage t he starter . Activate the starter for a maximum of five seconds, releasing the key when the en gin e starts. 9. If the engine do es not start, return the key to the OFF posit ion and wait five seconds before attemptin g to start again. Activate the starter [...]

57 OPERA TION Cold W eather Operation If the A TV is used year-round, check the oil level frequently . A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the cran kcase. W ater in the bottom of the crankcase can lead to engine damage and must be drained. W ater accu- mulation increases a[...]

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 TION Hauling Cargo WA RN I N G Overloading the vehi cle or carrying or towing cargo improperly can alter vehicle handli ng and may cause loss of c ontrol or brake instability , which ca n result in serious injury or death. Always follow these precautions when hauling carg o: REDUCE SPEED AND ALL OW GREA TER DIST ANC ES FOR BRAKING WHEN HAU[...]

60 OPERA TION Driving Safely Driving Procedures 1. W ear protectiv e ridin g ge ar . See pa ge 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 determine your path of travel. 6. Release the parki[...]

61 OPERA TION 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 directio[...]

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 TION 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 void steep hills (25 ° maximum). 4. Keep both feet on the footrests . 5. Shift your weight uphill. 6. Proc[...]

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 maintain[...]

65 OPERA TION 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 your[...]

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 Descent Control, engag e A W D. See pa ge 45. 3. Leave the transmi[...]

67 OPERA TION 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. Proc[...]

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 RN I N G 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 TION 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 P olari[...]

70 OPERA TION Driving Safely P arking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow t hese precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking b rake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off.[...]

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 ri odic 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 in tenance ch art . Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals[...]

73 MAINTENANCE P e ri odic Maintenance 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 RN I N G Imp[...]

74 MAINTENANCE P e ri odic 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 Cal[...]

75 MAINTENANCE P e ri odic 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)[...]

76 MAINTENANCE P e ri odic 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) 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 factory , and no additional lub rication will b[...]

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 127 for the part num- bers of Pol[...]

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 contaminants 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 v[...]

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. Allow it t o 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 recomme nd the use of Polaris Premium AGL Synthetic Gearca se Lubricant. See page 127 for the part numbers of Polari[...]

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 o rqu e to 22 ft. lbs. (30 Nm). 5. Add 32 oz. (9 48 ml) of the recommended oil. 6. Reinstall the fill plug. T orque to 22 ft. lbs. (30 [...]

85 MAINTENANCE F r ont 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 demand 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 eq uipped 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 maintena nce. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart begi[...]

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 coolant le vel is controlled, or maintained, 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 the[...]

89 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its 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 recove[...]

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 le ve l is low and the diaphragm is not extended, a leak is l[...]

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. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead positi on. 3. T ie a length of strin g between two stands as shown in the illustration[...]

92 MAINTENANCE Steering 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 foun d, see your Polaris dealer for service before ope rating the v ehicle. 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, pu[...]

93 MAINTENANCE Tires Refer to the specifications section beginning on page 128 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 ser[...]

94 MAINTENANCE Tires Wheel Installation 1. Place the transmission in P ARK. 2. Lock the parking b rake. 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 ground . 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 pod. 3. Lif[...]

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 orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition after[...]

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 t he 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. T urn the f[...]

103 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge acc umulated carbon from the exha ust pipe/m uf fler . 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 RN I N G 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 its 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 system to be[...]

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 recharge as needed to mainta in a full char ge . NOTE: Powe[...]

111 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t damage from le ak- ing or spilled ele ctrolyte during charging. See page 108. 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 spec ific grav- ity to 1[...]

112 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before 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 batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required[...]

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 components. 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, cleaning[...]

114 MAINTENANCE Cleaning and Storage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A v oid 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 coastal areas) are more su sceptible to corrosion if not properly clean[...]

116 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. Se e 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 recommen de d amount. NOTE: Ca[...]

117 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the flu id levels. Add or change flui ds as recommended in the Periodic Maintenance Char t beginni ng on page 72. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change [...]

118 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables a nd lubricat e 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 parking b rake. 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 spring 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 . Handlebars The handlebars can be adjusted for ri[...]

121 ADJUSTMENTS Carburetor Y our Polaris A TV is calibra ted at the factor y for optimal performa nce at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or hi gher . Above 6000 feet (180 0 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for e[...]

122 ADJUSTMENTS 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 and slide it far enough to expose the en d of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

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 ails to Start Engine Backfires Possible Cause Solution T ripped circuit breake r Reset the breaker 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 [...]

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 recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range S et 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 Overuse of chok e Inspect , clea n and/or replace spark p lugs W ater is present in fuel Replace with new fuel Foule[...]

127 POL ARIS PRODUCTS Pa rt Number Description Engine L ubricant 2870791 F ogging Oi l (12 oz. Aerosol) 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 ransmis sion Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603 [...]

128 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 Gross V ehicle W eight 1200 lbs. (544 kg) Maximum W eight C apacity 485 lbs. ( 220 kg) (operator , cargo , accesso- ries ) Dry W eight 696 lbs. (316 kg) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil Capa city 32 oz. (948 ml) Demand Drive Fluid [...]

129 SPECIFICA TIONS Jetting Chart Clutching Ch art Sportsman 500 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Front Suspension MacPherson st rut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift T ype Side Lever (H/L/N/R/P) Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 1[...]

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 W ARR ANTIE S AND REMEDIES The Polaris l imited warranty e xcludes any fa ilu res that are not c aused by a defect 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[...]

132 W A RRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED T O THE IMPLIED W ARRANTIES 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 THER DI SCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some states do not allow limi- tations on [...]

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 export from Polaris Industries. Deal[...]

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 wh ich 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 h[...]

135 W ARRANTY U.S.A . EP A Emiss ions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited 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 / COMMEN TS[...]

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