Polaris Sportsman 9921828 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 th is product contains chemicals known to the Stat e of California to cause cancer , birth [...]

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 Polari s Indus- tries Inc. Copyright 2008 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 discr[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . .[...]

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

5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate . This vehicle ha ndles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuv[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using yo ur key number) and mating it wi th one of your ex isting keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchase d your new A TV , your dealer instru cted you on the a uthorized A TV Rider- Course sm available to you and your eligib le family members. This train- ing is included in the purchase pri ce of your A TV . Polaris strongly encourages you and y our eligib[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the 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 the[...]

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

10 SAFETY Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See th e OPERA TION section of the owner ’ s manual for proper operati ng procedures. Operating Without Instr[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive u nder certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventil ated area. • Do not smoke or allow open flames or sparks in or near the area where refu- [...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e withou t wearing an approved helmet and protective eyewe ar increases the risk of a serious inj uries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield). Using Alcohol or Drugs O[...]

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

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

15 SAFETY Safety W arnings Descending Hill s Impr oper ly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hi ll s as de scri b e d in the own e r 's manual. NOTE: A special techn ique is required when braking while traveling do wn- hill. See page 57. • Always d[...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or impr operl y dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descendin g a hill. See page 36. If all forward speed is lost: •[...]

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

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could resul t in a collision with an obstacle or person. Always follow prope r op erating procedures as outli ned in this manual. See page 61. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When i t's safe to p[...]

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

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cau se changes in handling, which could cause loss of contro l or an acciden t. • Never exceed the stated load capa city for this A TV . • Cargo should b e properl y distributed and securely attached. • Reduce speed when carrying ca[...]

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

22 SAFETY Safety Labels and Locations W arning labels have been placed on the A TV for your protec tion. Read and follow the instructions of the la bels on the A TV carefully . If any of the labels depicted in this manual differ from the labels on your A TV , always read and follow the instruc tions of the labels on the A TV . If an informational o[...]

23 SAFETY Safety Labels and Locations T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause lo ss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 485 lbs. (220 kg) 7175642 + + T ire Pressure/L o[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Age 16 W arning W ARNIN G Operating this A TV if you are unde r the age of 16 increases your chan ce of severe injury or d eath. NEVER operate this A TV if y[...]

25 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o prevent 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 in jury or [...]

26 FEA T URES 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. W ARNING! Pressing the override button while th e thro ttle is open can cause loss of control, wh ich may resu lt in seri ous injury o r death. Alway[...]

27 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. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main K ey Switch Use t[...]

28 FEA T URES AND CONTROLS Throttle Lever Operating an A TV with sticking or impr operly operating throttl e controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th ro ttle. Always c ontact your deal er for service before operating the vehicle. Failure to check or ma intain proper operati on[...]

29 FEA T URES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of brak ing, which could cause an accident. Neve r operat e th e A TV with a spongy-feeling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handlebar to ap ply the front and r[...]

30 FEA T URES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may cause brake drag or b rake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygrosco pic, meaning it rapidly absorbs moisture from th[...]

31 FEA T URES AND CONTROLS Parking Brake Locking the Parking 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 brake lever[...]

32 FEA T URES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous in jury or death. Never ba ck down a hill. Use caution when applying the a uxiliary bra ke. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may[...]

33 FEA T URES AND CONTROLS Fuel T ank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pum p octane nu mb er of 87=(R+ M/2) oc tane . Do not use E-85 fuel . Fuel Filter The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel be[...]

34 FEA T URES AND CONTROLS All Wheel Drive System The All Wheel Dr ive s ystem is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 36. 4X4[...]

35 FEA T URES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially , the vehicle's electr onic sy stem will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remai ns enabled until the 4X4 switch is turned of f. If the switch is turn ed off while the d[...]

36 FEA T URES AND CONTROLS Active Descent Cont rol (ADC) System The ADC system allows engine brak ing to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will auto matically engage when all four of the follow- ing [...]

37 FEA T URES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In additi on to showing veh icle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also include[...]

38 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. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cl uster may hav e shut of f to protect the [...]

39 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Standard Mode s Use the MODE button to toggle thro ugh the mo de options. The reverse override button is also the MODE bu tton. See page 26. The transmission cannot be in reve rse wh en using this feature. Odometer Mode The odom eter record s the mile s travel ed by the A TV . T[...]

40 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 the[...]

41 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Scr een V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. 4X4 Diagnost ic Sc reen The gauge indicates whether or not current is flowing through the all- wheel-drive coil. This screen [...]

42 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 service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Cent[...]

43 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your Polaris de aler fo r all major repairs. See page 45 for Blink Codes and Failu re Descriptions. Use the follow- ing procedure to do wn load blink codes (failure codes) from the EFI mod[...]

44 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the cha rt (injector , fuel pump , etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed i[...]

45 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailu re Description 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 25 Gear Sensor Signal 31 System V oltage Low 31 System V oltage High 36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Loa d/Short-to-Ground [...]

46 OPERA TION Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’ s manual. Break-In Period The break-in period fo r your new Polaris A TV is the first ten ho ur[...]

47 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

48 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 29 85 Brake fluid Ensure pro[...]

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

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

51 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged. 4. Sit on the vehicle and move the [...]

52 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e foo trests and both 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 parking brake. 7. Sl[...]

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

54 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before whee ls begin to lose traction. NOTICE: Seve[...]

55 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of c ontrol or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 2. Drive straight uphill. 3. [...]

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

57 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 2. A void steep hills (25 ° maximum ). 3. Shift body weight uph ill. 4. Drive straight downhill. 5. Slow down. Excessive speed wh en traveling downhill can cause loss of contr[...]

58 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping b ody weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 3. Leave the transmission in f[...]

59 OPERA TION Driving Through W ater Y our A TV can op erate through 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 entering water . 2. Choose a crossing where both banks hav e g radual inclines. 3. A void opera[...]

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

61 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or people behind the vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turnin g at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button [...]

62 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these p recautions when hauling ca rgo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARG[...]

63 OPERA TION Hauling Cargo Never exceed the weight capac- ities specified for your A TV on warning labels an d in the speci- fications section of this manual. Car go weight should be evenly distributed (1/3 on th e fro nt rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, re duce speed and ca[...]

64 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S t op 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.[...]

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

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

67 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedure s marked with a  could resu lt in component failure and cause an accid ent, wh ich ma y result in seri ous injury o r death. Always have an authorize d Po la ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles su[...]

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

69 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. 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 50[...]

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

71 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 66. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be neede[...]

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

73 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 66. 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 t op the engine. 4[...]

74 MAINTENANCE Engine Oil Oil and Filter Change 10. Reinstall the screen fitting and ro tate the fitting clockwise a mini- mum of 2 1/2 turns into the tank thr eads. Continue to rotate the fit- ting until the nipple of the fitting a ligns with the mark on the tank. Tip : Do not over-tighten. Maximum to rq ue for the screen fitting is 25 ft. lbs. (3[...]

75 MAINTENANCE Engine Oil Oil and Filter Change 17. Reinstall the drain plug. The sealing surfaces on the drain plug and crankcase should be clean and fre e of burrs, nicks or scratches. T orque to 14 ft. lbs. (19 Nm). 18. Remov e the dipstic k. 19. Add two qu arts (1.9 l) of recommended oil. Reinstall the dipstick. Tip : If the su mp is not draine[...]

76 MAINTENANCE Engine Oil 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&apos[...]

77 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 66. 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 123 for the part numbers of Polari[...]

78 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 recommended oil. 6. Reinstall the fill plug. T orque to 22 ft. lbs. (30 Nm[...]

79 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginn ing on page 66. W e rec- ommend the use of Demand Drive L T Premiu m Fluid. Use of other fluids may result in improper operati on of components. See p age 123 for the part numbers o[...]

80 MAINTENANCE Front Gearcase (Dem and 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.[...]

81 MAINTENANCE Active Descent Control (ADC) Fluid T wo fluid levels must be maintained on your vehicle, th e demand drive fluid and the ADC fluid. See page 7 9 for demand drive fl uid mainte- nance. Check and change the ADC fluid leve l at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain t he fluid level betwe[...]

82 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 clean the areas arou nd and on the ADC reserv oir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and d[...]

83 MAINTENANCE Cooling System The engin e coolan t level is controlled, or main tained, 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[...]

84 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[...]

85 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[...]

86 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) to e out. W ARNING! Severe injury or death can result from improper toe alig nment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perf[...]

87 MAINTENANCE S teering Assembly The steering assemb ly of the A T V should be che cked periodica lly 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 Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. W ith a firm motion, p[...]

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

89 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parkin g brake. 3. Place the wheel on the hub with th e valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation. 4. Install the wheel nuts and finger -tighten them. 5. Lower the veh icle to the grou nd. 6. T orque the [...]

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

91 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replac ement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are pro- vided in a compartment on the top of the ac cess door . 1. Open the front box cove[...]

92 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps pro mptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a ha logen lamp, don[...]

93 MAINTENANCE Light s 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 ce[...]

94 MAINTENANCE Light s 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 s[...]

95 MAINTENANCE Light s 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 t[...]

96 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifi cations sect i on beg inn ing on p age 1 24 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs t o specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plug[...]

97 MAINTENANCE Spar k P l ug s S p ark 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. The tip should not be flaky and wh ite. A white insulator ti[...]

98 MAINTENANCE V ehicle Immersion If your vehicle bec om es immersed, majo r engine damag e ca n result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow t he steps outlined below . 1. Move the A TV to dry land o[...]

99 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warni ngs while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging. [...]

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

101 MAINTENANCE P VT 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 d[...]

102 MAINTENANCE P VT System When T o Use Low Range and High Range P VT 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 th[...]

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

104 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[...]

105 MAINTENANCE Battery Battery Inst allatio n 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 107 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery [...]

106 MAINTENANCE Battery Batter y S tor age 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. Power p[...]

107 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 104. 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 [...]

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

109 MAINTENANCE Cleaning and S torage W ashing 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. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, inclu[...]

110 MAINTENANCE Cleaning and S torage W ashing the 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 direc ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals •[...]

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

112 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S tarting the engine durin g the storage perio d will di sturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge peri od. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 109. Stabilize[...]

113 MAINTENANCE Cleaning and S torage Sto r a g e 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 6 6. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • T ransmission • Brake fluid ([...]

114 MAINTENANCE Cleaning and S torage Sto r a g e 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 66. Battery Storage See pages 106-107 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely suppor t the A TV [...]

115 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S t op 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 [...]

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

117 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adjustment of th e hand leba rs or incorrect torquing of the adjuster block tightenin g bolts can caus e limited steeri ng or loosening of the handlebars, resulti ng in lo ss of control and serious injury or death. Follo w the adjustment procedures ex[...]

118 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 Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and[...]

119 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 58). 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[...]

120 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art 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, [...]

121 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith 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([...]

122 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line 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[...]

123 POLARIS PRODUCTS Pa r t Number Description Engine L ubricant 2870791 F oggin g Oil (12 oz. Aeroso l) 2876244 PS-4 PL US P e rformance Syntheti c 2W -5 0 4-Cycle Oil (qt.) 2876245 PS-4 PL US P e rformance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / T ra nsmission L ubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603[...]

124 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 EFI Maximum W eight Capacity 485 lbs. (220 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) Demand Drive Fluid Capacity 9.3 oz. (275 ml) T ransmission Oil Capa city 32 oz. (948 ml) Front Rack/S torage Box Capacity 90 lbs. (40[...]

125 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment 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 (34.5 KPa) T ires/Pressure, Rear 26x1 1-12 / 5 psi (34.5 KPa) [...]

126 W ARRANTY 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 c[...]

127 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANT IES AND REMEDIE S 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 [...]

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

129 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE 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. D[...]

130 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private 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 hav[...]

131 W ARRANTY U.S.A. EP A Emission s Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V e hicle (ORUV) emissions lim it 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 t[...]

132 MAINTENANCE LOG 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[...]

133 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]