Polaris Sportsman 9921837 manual

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1 WELCOME Thank you for purch asing a Polaris vehicle, an d welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line o f utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • Quadricycles/T ractors • RANGER utility vehicles • V ictory motorcycles Always follow the instructions [...]

2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks of Pola ris 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 discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their me anings befor e r eading the manual. The safety ale rt symbol indicates a potentia l personal injury hazard. W ARN ING A W ARNING indicate s a haz[...]

5 INTRODUCTION Failure to follow the warni ngs in this manual can result in se rious injury or death. A Polaris T ractor is no t a toy and can be hazardous to operate. A co llision or rollover can occur q uickly , even duri ng routine maneuvers, if you fail to take proper precaution s. • Read this owner ’s manual. Understand all sa fety warni n[...]

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 with o ne of your existi ng keys. The ignition switc[...]

7 SAFETY Safety T raining When you purchased your new T rac tor , your dealer offered a hands-on safety training course. Y ou were al so provided with printed materials that explain safe op erating procedur es. Review this information on a regular basis. If you purchased a used Polaris T ractor from a party other than a Polaris dealer , please requ[...]

8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca na da bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE ma[...]

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 Rider Safety Serious injury or death can result if you do not follow the instruction s and procedures listed here a nd throughout this manual . Read and understand all warnings, cautio ns and operating procedures in this manua l and on the safety labels before operating the T ractor . Never operate a T ractor witho ut proper instruction. [...]

11 SAFETY Rider Safety Never carry a passenger on thi s vehicle. Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, lo ng sleeves and long pan ts . Never consume alcoho l or drugs before or while opera ting a T ractor . Never operate at excessive speeds. T ravel and turn at speeds approp[...]

12 SAFETY Rider Safety Always inspect your T ractor before each use to verify that it's in safe operating condition. Follow the insp ection and maintenance procedures outlined in this manual. See page 41. Keep both hands on the handlebars. Keep both feet on the footrests. Always travel slowly when ope rating on unfamiliar terra in. Use extra c[...]

13 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outline d in this manual for driving on hi lls. See page 46. Never operate on hills too steep for the T ractor or for your abil ities. Practice on smaller hills before attempting la rger hills. Avoid climbing hills ste eper than 2 5 ° . Always move the 4X4 swi[...]

14 SAFETY Rider Safety Always follow the procedures outline d in this manual for bra king if you stall or roll backwards while climbing a hill. Never back down a hill. See page 50. Always follow the procedures outl ined in this manual for operatin g over obstacles. See p ag e 55. Always follow the procedure s outlined in this manual for operating o[...]

15 SAFETY Rider Safety Always follow the procedures outl ined in this manual for driving in re verse. See pa ge 56. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a T racto r through improper installation or use o f accessories. Never exceed the stated load capacity for your vehicle[...]

16 SAFETY Rider Safety Never operate the T ra ctor on a frozen body of water . Operating on paved surfaces may affect the handling and control of the T ractor a nd could result i n loss of control. Avoid sudden turns or swif t movement of the handlebars. Always remove the ignition key when the vehicle i s not in use to prevent unauthorized use o r [...]

17 SAFETY Safety Labels and Locations W arning labels have been plac ed on the vehicle for your protec tion. Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement safety labe ls are provided by Polaris at no charge. The part number is[...]

18 SAFETY Safety Labels and Locations Tire Pressure/Load Alert TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5 ) MAXIMUM WEIGHT CAP ACITY 420 LBS. (191 kg) INCLUDES WEIGHT OF OPERA T OR, CARGO AND ACCE SSORIES. Read Owner's Manual for more detailed loading information . 7174877 Reverse Overrid e Alert/4X4 (A WD) Switch W ARNIN G Pushin[...]

19 SAFETY Safety Labels and Locations “No P assenger” W arning W ARNING NEVER ride as a p assenger . Passengers can cause a lo ss of control, resu lting in SEVERE INJUR Y or DEA TH. 7175378 Clutch Cover Alert NO STEP 7173030 Rack W arning W ARNING • DO NOT TO W FROM RACK OR BUMPER. V eh icle damage or tipover may result causing severe injury [...]

20 FEA TURES AND CONTROLS Switches Master Light Switch The master light switch must be in th e ON position to allow operation of the headlights, parking lights and taillights. Mode/Reverse Ov erride Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 31. T o gain additional power whil e opera ting i[...]

21 FEA TURES AND CONTROLS Switches Main K ey Switch End all electrical power to the vehicle. The LIGHTS ON position turns the headlights on. The master light switch must be on and the engine stop switch must be in the RUN position. S tart the engine. The h eadlights are not on in this position. After starting the engine, release the key switch to t[...]

22 FEA TURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to en gage ADC 4X4, 4X4 or 2X4. See page 28. Hazard W arning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously . Use this feature to alert others of an emer gency or other situation requiring caution. T urn Signal Switch Push the toggle swit[...]

23 FEA TURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the T ractor . Throttle Lever Failure to check or maintain prope r operation of the throttle system can result in an accident if the throttle lever sticks during operati on. Check the lever for proper operation before[...]

24 FEA TURES AND CONTROLS Brakes Aggressively applying the brakes whe n backing down a hill may cause rear tipover . Aggressively applying the br akes while moving forward may cause the rear wheels to skid and result in loss of control. Read th is owner's manual and understand the operation of all brake systems on this vehicle. Always use caut[...]

25 FEA TURES AND CONTROLS Seat Seat Load Adjustment Adjust the seat spring for the comfort of a lighter or heavier operator . Reach under the rear rack to access the adjuster . T ighten the spring for heavier riders. Loosen the spring for lighter rid- ers. Use the following table to determine the best preload measurement for rider weight. Measure p[...]

26 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle. The handlebars are locked in the fully turned position when the steering is locked. Always unlock the stee ring before starting the engine. 1. T urn the handlebars to the full right position. The handlebars may al so be locked in the fu l[...]

27 FEA TURES AND CONTROLS Hitches Hitch Installation/Removal 1. Release the wire lock from the 12.7 mm pin and remove the p in. 2. Install the hitch to the receiver . 3. Install th e 12.7 mm pin throug h the bore of both the receiver and the hitch. Secure the wire lock. Make sure the hitch assembly is secure at that the wire lock is properly engage[...]

28 FEA TURES AND CONTROLS All Wheel Dri ve (4X4) System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 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 befor e asce nding or descending a hill. See page 30. 4X[...]

29 FEA TURES AND CONTROLS All Wheel Dri ve (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is movin g. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4. If the switch is turned of f wh[...]

30 FEA TURES 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 c[...]

31 FEA TURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. In addition to showing vehicle speed, th e speedometer need le flashes when a warning condition exists. The instrum ent cluste r measures dist ance in miles or kilometers, as well as hours of operation. It also incl udes a reverse speed l[...]

32 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. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cluste r may have sh ut of f to protect the e[...]

33 FEA TURES 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 20. The transmission cannot be in reverse wh en using this feature. Odometer Mode The odometer records the miles or k ilometers traveled by the[...]

34 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. 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[...]

35 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. 4X4 Diagnost ic Screen The gauge indicates whether or not curren t is flowing through the 4X4 coil (only on models with switcha[...]

36 FEA TURES 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 oggl e 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[...]

37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and od ometer can be changed to display either standard or metr ic units of measureme nt. 1. Enter the diagnostic mode. 2. T oggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and h[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blin k once, pause, then blink twice (blink code 12) to be gin the diagno stic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code. 4. Count the number of times th e[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Descript ion 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 3[...]

40 OPERA TION Break-In P eriod The break-in perio d for your new Polari s T ractor is the first ten hours o f operation, or the time it takes to use the first two full ta nks of gasolin e. No single action on your part will in crease the life an d per formance of your T racto r more than following th e procedures for a proper break-in. Careful trea[...]

41 OPERA TION Pre-Ride Checklist Item Remarks P age Hand brake/lever travel Ensure proper operation 83 Foot brake Ensure proper operation 83 Brake fluid Ensure proper level 83 F ront su spension Inspect, lubricate i f necessary 65 Rear suspension Inspect, lubricate if necessary 65 Steering/steering lock Unlock the steering ; ensure free oper- ation[...]

42 OPERA TION Starting the Engine NOTICE: Operating the vehicle immediate ly after st a rting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK (or neutral). 3. Sit on the vehicle. 4. Apply the brakes. 5. Move the engine stop sw[...]

43 OPERA TION Cold W eather Operation Internal engine condensation in creases as outside tempe ratures decrease. If the vehicle is used ye ar-round, check the oil level fre- quently . A rising oil level could indi cate condensation in the bottom of the oil tank, which can lead to en gine damage. Any condensation must be drained. Always operate the [...]

44 OPERA TION Driving Procedures 1. W ear protectiv e riding gear . See page 8. 2. Perform the pre-ride inspection. See page 41. 3. Sit upright. Keep your feet o n th e footrests. K eep both hands on the handlebars. 4. S tart the engine and allow it to warm up. 5. Apply the brakes. 6. Shift the transmission into gear . 7. Check you r surroundings a[...]

45 OPERA TION T urning the V ehicle 1. Before turning, activate a turn signal to alert oth- ers of your intentio ns. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. S teer in the direction of the turn, leaning your upper body to the in side of the turn while sup- porting your weight o n the outer foo[...]

46 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 30. 2. A void steep hills (25 ° maximum). 3. A void hills with sli ppery or loose surfaces. 4. Keep both feet on the footrests . 5. Shift body weight up hill. 6. Drive straight [...]

47 OPERA TION Driving Uphill If all forwar d speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r olling backwar ds. 1. Apply the brakes gradu ally . 2. When fully stopped, loc k the hydraulic parking br ake. 3. Dismount on the uphill side, or on the[...]

48 OPERA TION Driving on a Sidehill (Sidehilling) A void crossing the side of a hill (sid ehilling) if possible. If sidehilling is necessary , follow these precautions: 1. Slow down. 2. A void hills with sli ppery or loose surfaces. 3. A void crossing the sides of steep hills. 4. Shift your weight uphill. 5. Keep your feet on the footrests. 6. If t[...]

49 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. A void steep hills (25 ° maximum). 3. A void hills with sli ppery or loose surfaces. 4. Never drive downhill at high speed. Slow down. 5. Drive straight downhill. A v oid dr[...]

50 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 the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 30. 3. Lock th e hydrau lic parking brake. 4. Leave the [...]

51 OPERA TION T urning Around on a Hill (K - T urn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side . Keep your weight uphill. 1 1. Apply the foot brake. 12. W ith the transmission still in forward, start the engine. 13. Squeeze and release the brake le ver to release the parking brake . 14. Release the foot brake and drive sl[...]

52 OPERA TION Driving Through W ater Follow these procedures wh en driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual in clines. 3. Drive slowly . A void rocks and obstacles. 4. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel[...]

53 OPERA TION Driving Through W ater If your vehicle becomes fully immersed , and it's impossible to take it to a dealer before starting it, follow the steps described on page 98. Have the vehicle serviced by your dealer promptly . Always follow the procedure s outlined in this manual for driving thro ugh water . Never d rive through deep or f[...]

54 OPERA TION Driving on Slippery Surfaces Always follow the pro cedures outlined in thi s manual for operatin g on slippery or loose surfaces. Use extra caution. Always avoid skiddin g or sliding. Whenever driving o n slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down be fore driving onto sli[...]

55 OPERA TION Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void ha zards such as logs, rocks and low branches. P arking on an Incline A void parking on an incline. If it's unavoidable, follow these precautions[...]

56 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or peop le behind the vehicle before backing. 2. A void backing downhill. 3. Drive slowly . Apply the brak es lightly for stopping. 4. A void turning at sharp ang les. 5. Never open the throttle suddenly . 6. Do not use the override sw[...]

57 OPERA TION Hauling Cargo Overloading the vehicle or carryi ng or towing cargo impr operly can al ter vehicle handling and may cause loss of control or brake instability . Alwa ys follow these precautions when hauli ng cargo. • Read and understand the load distribut ion warnings liste d on the vehicle warning labels. • NEVER EXCEED THE MAXIMU[...]

58 OPERA TION Hauling Cargo Always read and understand the load di stribution warning labels on the vehicle. Neve r exceed the weight ca pacities specified for this vehicle. T owing Loads T owing is approved OFF-ROAD ONL Y . Operating a T ractor/trail er combination on public roads is prohib ite d. See your Polaris dealer about configuring the vehi[...]

59 OPERA TION Hauling Cargo T owing Loads Using an improper hitch or exceeding the maximum tongue weight capa city can result in serious damage to the vehicle and will void your warranty . Never install a hitch lo nger than 10 cm. Never install au to- motive accessories on your P ola ris T ractor . Always install Po laris-approved (or equi valent) [...]

60 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requirements. Spark Arrestor Y our Polaris vehicle has a spark arrestor tha t was designed for on-road and of f-road operation. It is required that this spark arrestor re[...]

61 MAINTENANCE P eriodic Maintenance Char t Maintena nce interval s in the fo llowing ch art are ba sed upon averag e riding conditions. V ehicles subjected to severe use mu st be inspected and serviced more frequently . The programmable service interval mo de on the instrument cluster will help determine when maintenance service is due. See page 3[...]

62 MAINTENANCE P eriodic Maintenance Char t Improperly performing the procedures marked with a  could re sult in component failure an d lead to seriou s injury or death. Have an auth orized Polaris dealer perfo rm these services. Maintenance Chart K e y X Perform these operations more of ten for vehicles subjected to severe use. E Emission-relat[...]

63 MAINTENANCE P eriodic Maintenance Char t Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Kilometers X E Air filter , main element - Weekly - Inspect; replace as needed X Q Brake pad wear 10 Monthly 160 Inspect periodically Battery 20 Monthly 320 Check terminals; clean; test X Demand drive fluid 25 Monthly 400 Inspect lev[...]

64 MAINTENANCE P eriodic Maintenance Char t 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 Kilometers Q E V alve clearance 100 12 M 1600 Inspect; adjust Q E F u[...]

65 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintena nce Chart beginni ng on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-ar ms and upp er control a rms are lubricated at the factory, and no additional lubrication wi ll be n[...]

66 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changi ng oil. 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 [...]

67 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. S tart the engine. All ow it to idle for 30 seconds. 4. S top the engine. 5. Remove the dipstick . W ipe it dry with a cl ean cloth. 6. Reinstall the dipstick completely . 7. Remove the dipstick and check the oil level. Add oil as [...]

68 MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. S tart the engine. All ow it to idle for 30 seconds. 4. S top the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the oil tank. 7. Remove the drain plug. 8. Drain the oil. Hot oil may result [...]

69 MAINTENANCE Engine Oil Oil and Filter Change 1 1. Disconnect the lower oil deliv- ery hos e and remove the screen fitting from the oil tank. Clean the fitting. Seal the fitting threads with LOCTITE PST 505 or P TFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continu[...]

70 MAINTENANCE Engine Oil Oil and Filter Change 20. Remov e the dipstic k. 21. Add 1.9 liters of recommended oil. TIP: If the sump is not drained, ad d about 1.6 liters ini tially . 22. Reinstall the dipstick. 23. Place the transmission in P ARK. 24. Prime the oil pump using the procedur e on page 71. 25. S top the engine. Check for oil leaks. 26. [...]

71 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming proced ure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fit ting and the vent line's pressure relief slit. 2. S tart t[...]

72 MAINTENANCE T ransmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 1 18 for the part numbers o f Polaris products. T ransmission Oil Recommendations T ransmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. C[...]

73 MAINTENANCE T ransmission Oil T ransmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. T orque to specification. See page 72. 8. Add the recomme nded oil. See [...]

74 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Recommendations Use the recommended fl uid. Use of other fluids may result in improper operation of components. See page 1 18 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads. Fluid Level 1. Position the vehicle on a level surface. 2. [...]

75 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. T orque to specification. See page 74. 7. Add the reco mmended flu[...]

76 MAINTENANCE Active Descent Control (ADC) Fluid The ADC fluid reservoir is located un der the front box. Th e reservoir cap is yellow . W e recommend the us e of Polaris ADC Fl uid. See page 1 18 for the part numbers of Polaris products. Fluid Level 1. Position the vehicle on a level surface. 2. Open the front box cover . 3. Open the access door [...]

77 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[...]

78 MAINTENANCE Cooling System Any time the cooling system has been drained for maintena nce or repair , replace the coolant with a fresh mixture of antifreeze and water . Drain the cooling system every two years. Add fresh coolant. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high qua lity aluminum[...]

79 MAINTENANCE Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover . 2. Open the access door . 3. Remove the radia tor pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck. 5. Reinstall the pressur[...]

80 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride . Always maintain brake fluid at th e recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or lo w fluid level. A low flui d level may also mean that brake pads are wo rn [...]

81 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handle- bar . Maintain the fluid level 6 mm below the top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew the fluid level through the indicator win- dow (eye) on the top of the m[...]

82 MAINTENANCE Brake Fluid F oot Brake The foot brake fluid reservoi r is located under the seat. 1. Position the vehicle on a level surface. 2. Remove the seat. 3. V iew the fluid level in the reservoir . 4. Remove the cap and ad d the recommended fluid as needed. 5. Maintain the fluid level between the minimum and maximum marks. Do not overfill. [...]

83 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake . The handlebar brake is also hy draulic. Both brake systems are self-a djusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under [...]

84 MAINTENANCE T oe Alignment Do not attempt to adjust ali gnment. All steering ad justments should be performed by an authorized Polaris deal er . Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the ha ndlebars in a straigh[...]

85 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loo se nuts and bolts. If loose nuts and bolts are foun d, see your Polaris dea ler for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference. Improper adjustment of th e handlebars or inco rrect torq[...]

86 MAINTENANCE Side P anel Removal 1. Remove the seat. 2. Grasp the rear of the side pa nel near the rear cab. 3. W ith a firm moti on, pull the panel outward to disengage the side panel from the g rommet. 4. Pull the panel downward and rearward to remove it. F ootwell Removal 1. Remove the si x screws on the bottom of the footwell. 2. Use a flat s[...]

87 MAINTENANCE 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 1.6-3.2 mm[...]

88 MAINTENANCE Tires Operating your veh icle with worn tires, imprope rly infl ated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. Always follow all tire ma int enance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type[...]

89 MAINTENANCE Tires Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Loosen the wheel nuts slightly . 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5. Remove the wheel nut s. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install t[...]

90 MAINTENANCE F uel Filter The in-line fuel filter should be repl aced by your dealer after every 100 hours of operation or annually . Do not attempt to clean the fuel filter . Air Filter Always clean and replace the air and br eather filters at the intervals out- lined in the Periodic Maintena nce Chart b eginning on page 61. 1. Position the vehi[...]

91 MAINTENANCE Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 86. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Repla[...]

92 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in P ARK. 3. Measure the distance from the floo r to the center of the headlight and make a mark on the wall at the [...]

93 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. W ash the headlights and taillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've coole d. Headlight/Position Light Lamp Replacement When servicing a halogen la[...]

94 MAINTENANCE Lights T aillight/Brake Light Lamp Replacement 1. Place the transmission in P ARK. 2. Rotate the taillight socket counter- clockwise to remove i t. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. T est the lamp for proper operation. 6. Reinstall all components in reverse order . F ront T urn Sig[...]

95 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electr ical fail- ures, a fuse may need replacement. Spare fuses are provided in a compart- ment on the top of the access door . 1. Open the front box cover . 2. Open the access door . 3. Remove the suspect fuse from the fuse panel. Install a new fuse[...]

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section begi nning on page 1 16 for the recom- mended spark plug type and gap for yo ur 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 the e[...]

97 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 86. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Tu r n t h e p l u g counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify tha t the gap is at specificat[...]

98 MAINTENANCE V ehicle Immersion If your vehicl e has been totally submer ged in water and it 's impossible to have it serviced before furthe r operation, perform the following pro- cedure. NOTICE: If the vehicle sto ps while fully submerged, major engin e damage can result if the machine is not thorough ly inspected. T ake the vehi cle to yo[...]

99 MAINTENANCE V ehicle Immersion 4. T urn the ignition key past the P ARKING LIGHTS position to engage the starter . Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or inst all a new plug. 6. T orque to specification. See page 96. 7. Attempt to start the engine. If necessary , repeat the drying procedure. 8. Have[...]

100 MAINTENANCE Spark Arrestor Failure to heed the following 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 comb ustible mate rials from the area . We ar eye protect ion and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging.[...]

101 MAINTENANCE Spark Arrestor 6. If carbon comes out of the exhaust, cover o r plug the exhaust outlet. W ear protective gloves. 7. Lightly tap on the exhaust pi pe with a rubber mallet while repeat- ing step 5. 8. If particles are still suspected to be in the muf fler , elevate the rear of the vehicle 30 cm higher than the front. Block the wheels[...]

102 MAINTENANCE PVT System 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 has been precision balanced. Any modi fication will cause the system to be out of balance, creating vibrati on and addi tional loads on componen ts. The PVT system rotates at high s[...]

103 MAINTENANCE PVT System PVT Drying There may be some instance s when wate r is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the drain plug. Allow the water to drain completely . Rein- stall the drain plug. 4. S tart the engine. 5. A[...]

104 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burn s can result from contact with skin, eyes or clothing. Antidote: External : Flush with water . Internal : Drin k large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately . Eyes : Flush wi[...]

105 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an e xplosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , a lways connect the negative (black) cable last. Battery Removal 1. Place the transmission in P [...]

106 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 st orage and recha r ge as needed to mainta in a full charge. Polaris reco[...]

107 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 105. 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[...]

108 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a volt meter or multimeter . A fully charged batt ery will register 12.8 V or higher . 2. If the voltage is less than 12.8 vo lts, recharge the battery at 1.2 amps or less until battery voltage is 12.[...]

109 MAINTENANCE Cleaning and Storage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. High water pressure may damage components. Polaris recommends washing the vehicle by ha nd or with a garden hose, using mild soap. Certain products, including ins[...]

110 MAINTENANCE Cleaning and Storage W ashing the 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 an d labels. A void direc ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals •B[...]

111 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C le[...]

112 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: S tarting the engine during the storage period will di sturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 109. Stabilize the F u[...]

113 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the flu id levels. Add or chan ge fluids as recommen ded in the Periodic Maintenance Char t beginni ng on page 61. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two ye[...]

114 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubric ate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 61. Battery Storage See pages 106-107 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the vehicle[...]

115 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in P ARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the T ractor to the transporting unit securely with suitable straps or [...]

116 SPECIFICA T IONS Sportsman 500 EFI T ractor Maximum W eight Capacity 420 lbs. (191 kg) (includes operator , carg o, acces- sories, tongue weight) Dry W eight 775 lbs. (352 kg) Front Rack/S torage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Rear Hitch T ongue Capacity 120 lbs. (54. 4 kg ) (Rear rack capacity and tongue weigh[...]

117 SPECIFICA TIONS Clutching (EBS Models) *EBS models require no helix/spring adjustment Sportsman 500 EFI T ractor T ransmission Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 2 1.74:1 Gear Reduction, High 10.57:1 Drive Ratio, Front 3.82:1 T ires/Pressure, Front 25x8-12 / 5 psi (34.[...]

118 POL ARIS PRODUCTS Pa r t Number De scription Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synt hetic 2W -50 4-Cycle Oil (.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W -50 4-Cycle Oil (3.8 l) Gearcase / T ransmis sion Lubricants 2873602 Premium AGL Synthetic Gearcase L ubricant (.95 l) 2873603 Premium [...]

119 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 50). Driving at l ow RPM or ground speed (5-1 1 kmh) Drive at a higher speed or use low range more frequently . Insuffici[...]

120 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solution Out of fuel Refuel Clogged fuel f[...]

121 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replac e with recom mended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plug(s)[...]

122 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 Inspect and repl ace (if equ ipped) W ater is present in fuel Replace with fresh recommen ded fuel Old or non-recommended fuel Replac e w[...]

123 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of th e Polaris T ractor against defects in material or workma nshi p. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are cove r ed by this warranty . [...]

124 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF W ARR ANTIES AND RE MEDIES The Polaris l imited warranty e xcludes any failu res that are not caused 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 wa rranty also does not c over any v[...]

125 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris T ractors. When requesti ng warranty service you must present your copy of the W arranty Registration form to th e dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RE SPONS[...]

126 MAINTENANCE L OG 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 KIL OMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

127 MAINTENANCE L OG DA TE KIL OMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

128 INDEX 0-9 4X4 System . . . . . . . . . . . . . . . . . 28-29 A Accessories . . . . . . . . . . . . . . . . . . 114 Active Descent Control Fluid . . . 76-77 Active De scent C ontrol Sys tem . . . . 30 ADC System . . . . . . . . . . . . . . . . . . 30 Air Filt er . . . . . . . . . . . . . . . . . . . . . 90 All Whe el Drive Switch. . . . . . . . [...]

129 INDEX F Fluid Change ADC Fluid. . . . . . . . . . . . . . . . . 77 Deman d Drive . . . . . . . . . . . . . . 75 Engine Oil . . . . . . . . . . . . . . 68-71 Front Gearc ase . . . . . . . . . . . . . 75 Transm ission . . . . . . . . . . . . . . . 73 Fluid Level ADC Fluid. . . . . . . . . . . . . . . . . 76 Brake Fluid . . . . . . . . . . . . . .[...]

130 INDEX O Oil Change Engine . . . . . . . . . . . . . . . . . 68-71 Transm ission . . . . . . . . . . . . . . 73 Oil Level Engine . . . . . . . . . . . . . . . . . . . 67 Transm ission . . . . . . . . . . . . . . 72 Oil Pu mp Prim ing . . . . . . . . . . . . . . 71 Oil Recommendations Engine Oil . . . . . . . . . . . . . . . . 66 Transm ission . [...]

131 INDEX T Tires . . . . . . . . . . . . . . . . . . . . . . 88-89 Wheel Installat ion . . . . . . . . . . . 89 Wheel Nu t Torque . . . . . . . . . . 88 Wheel Rem oval. . . . . . . . . . . . . 89 Toe Alig nment . . . . . . . . . . . . . . . . . 84 Towing a Dis abled Vehicle. . . . . . . 115 Towing Capaci ties . . . . . . . . . . . . . . 58 Towing [...]