Polaris Sportsman 9921792 manual

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For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9921792 Rev 02 Printed in U.S.A.[...]

1 WELCOME Thank you for purch asin g a Polaris vehicl e, and welcome to our world- wide family of Polaris owners. W e proudly pro duce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • Quadricycles • RANGER utility vehicles • V ictory motorcycles Always follow the instructions and recom[...]

2 POLARIS and POLARIS THE W A Y OUT are regi stered trad emarks 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 publication. Due to constant improvements in the design and quality of production compo nents, some minor discre[...]

3 T A BLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . . .[...]

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5 KNOW Y OUR VEHICLE As the operator of the vehicle, yo u are responsible for your persona l safety , the safety of others (including your passenger), and the protec- tion of our environm ent. Rea d and understand yo ur ow ner's manual, which includes valuable information ab out all aspects of your ve hicle, includi ng safe operati ng pro cedu[...]

6 SAFETY Rider Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their me anings befor e r eading the manual. The sa fety alert symb ol , on your vehicle or in this manual, alerts you to the potential for in jury [...]

7 SAFETY Rider Safety Safety T raining When you purchased your new Quadricycle, your deal er offered a hands-on safety traini ng course. Y ou were also provided with printed materials that explain sa fe operatin g procedures. Review this informa- tion on a regular basis. If you purchased a used Polaris Quad ricycle from a party other than a Polaris[...]

8 SAFETY Rider Safety Read and understand al l warnings, cautions and operatin g procedures in this manual and on the safety labels before operating the Quadricycl e. Never operate a Quadricycle without proper instructio n. T a ke a training course. Beginners should re ceive training from a certified instructor . Contact an authorized Polaris Quadr[...]

9 SAFETY Rider Safety Always wear an approved helmet that fits properly . W ear eye protection (goggles o r face shield), gloves, boots, long sleeves and long pants. Never consum e alcohol or drugs before or while operating a Quadricycle. Never operate at excessive speeds. T ravel and turn at speeds appropriate for the terrain, visibility , operati[...]

10 SAFETY Rider Safety Always inspect your Quadricycle before each us e to verify th at it's in safe operating conditi on. F ollow the inspection and maintenance procedures outlined in this manual. See page 43. Keep both hands on the h andlebars. K eep both feet on the footrests. A passenger should always be seated in the pa ssenger seat with [...]

11 SAFETY Rider Safety If a Quadricycle has be en involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not li mited to) brake , throttle and st eering systems. Always follow the procedures outlined in this ma nual for driving on hills. See page 50. Neve r operate on hills t[...]

12 SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never ba ck down a hill. See page 54 . Always follow the procedures outlined in this manual for operating over obstacles. See page 59. Always follow the procedures outlined in this manual for operating on sli[...]

13 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving in reverse. See page 6 1. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Quadricycle through improper installa tion or use of accessories. Never exceed the stated load capacity for yo ur vehicl[...]

14 SAFETY Rider Safety Never operate the Quadricycle on a frozen body of water . Operating on p aved surfaces may affect the handling an d control of the Quadricycle and could result in loss of control. Avoid su dden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle i s not in u se to prevent unauthorized us[...]

15 SAFETY Safety Decals and Locations W arning decals have been pl aced on the vehicle fo r your protection. Read and follow the instructions on each decal carefully . If a decal becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement sa fety deca ls are provided by Polaris at no charge. The part number i[...]

16 SAFETY Safety Decals and Locations Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KP a): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACI TY 568 LBS. (258 KG) INCLUDES WEIGHT OF OPERA TOR , P AS SENGER, CARGO AND ACCES SORIES. Read Owner's Manual for more detailed lo ading information. 7175164 Reverse Ov erride Alert Pushing reverse over[...]

17 SAFETY Safety Decals and Locations Rack W arning, F ront and Rear WARNING DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or tipover may result causing severe injury or death. T ow only from tow hooks or hitch. Maximum Rack Loads: F ront 90 lbs. (41 kg) Rear 180 lb s. (82 kg) 7172572 Clutch Cover Alert WARNING • Moving parts hazard under bel t[...]

18 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 b ear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE [...]

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

20 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32. T o gain additional whee l speed while operating in reverse, press the override switch before opening the th rottle. This will cancel the reverse speed limit function. NOTE: The override[...]

21 FEA TURES AND CONTROLS Switches Main K ey Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. S tart the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. Do not attach a large key fob or key rin g to the main switch. I[...]

22 FEA TURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to en ga ge ADC 4X4, 4X4 or 2X4. See page 30. 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 swi[...]

23 FEA TURES AND CONTROLS Switches Differential Switch Use the dif ferential switch to lock and unlock the rear differential. Locked Differ ential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differ ential: When the differential is unlocked, the inside wheel will rotate inde pendently from the out side wh[...]

24 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle move- ment. Release the lever to reduce engine speed and vehicle move- ment. Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before dr iving the Quadricycle. Electronic Throttle Control (ETC) ETC causes [...]

25 FEA TURES AND CONTROLS Fo o t B r a k e The all-wheel foot brake is located on the ri ght footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with yo ur foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure. Hand Brake Lever The hand br[...]

26 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in P ARK. 2. Squeeze the brake lever toward the handlebar . 3. Push the parking brake lock forward to engage the lock. Release the brake lever . 4. T o release the parking brake lock, squeeze and release the brake lever . W ARNING Operating the Qua[...]

27 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or th eft of the vehicle. 1. T urn the handlebars to the full right position. NOTE: The handlebars ma y also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key . NOTE: Place the steering lock keys in a s[...]

28 FEA TURES AND CONTROLS Fu e l T a n k C a p Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane of 87. D o not use E-85 fuel. F uel Filter The in-line fuel filter should be replaced by your dealer after every 100 h ours of op eration or annually . Do not attempt to clean the [...]

29 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selec tor is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in P ARK. The transmission is locked when it’ s in P ARK. Shifting gears with the[...]

30 FEA TURES AND CONTROLS All Wheel Dri ve (4X4) System The All Wheel Drive syst em 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 nd ing or descending a hill. See page 31. [...]

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

32 FEA TURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distanc e in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 1 1-14 km/h. Refer to page 20 for add[...]

33 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2. 5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a ba ttery over -vo ltage may have occurr ed and the in strument cl uster may have shut off to prote[...]

34 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ugh the mo de options. The rev erse override button is also the MODE button. See page 20. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or k ilometers traveled by[...]

35 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 [...]

36 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 Sc reen The gauge indicates whether or not current is flo wing through th e 4X4 coil (only on models with switc[...]

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

38 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 measurement. 1. Enter the diagnostic mode. 2. T oggl e to the screen that displays ei ther kilometers (KM) or miles (MP). 3. Press and [...]

39 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 b egin 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[...]

40 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[...]

41 OPERA TION F uel Safety W ARNING Gasoline is h ighly flammable and explosive under certain conditions. • Use ex treme caution whenever handlin g gasoline. • Refuel with the engine st opped. Refuel outdoors or in a wel l-ventilated area. • Never fill a fuel container while it's on the vehicle. Static electrici ty between the rack and c[...]

42 OPERA TION Break-In P eriod The break-in period for your new Po laris Quadricycle is the first ten hours of operation, or the time it take s to use the first two full tanks of gasoline. No single action on your part will increase the life and perfor- mance of your Quadricycle more th an foll owing the proc edures for a proper break-in. Careful t[...]

43 OPERA TION Pre-Ride Checklist Item Remarks P age Hand brake/lever travel Ensure proper operation 84 Foot brake Ensure proper operation 84 Brake fluid Ensure proper level 84 P assenger sea t latch Ensure latch is secure 29 F ront su spension Inspect, lubricate i f necessary 69 Rear suspension Inspect, lubricate if nece ssary 69 Steering/steering [...]

44 OPERA TION Starting the Engine Operating the vehicle immediately afte r sta rting could cause engine da mage. Allow the engine to warm up for several minutes before operatin g. 1. Position the vehicle on a level surface. 2. Place the transmission in PA R K . 3. Sit on the vehicle. NOTE: The starter in terlock will prevent the en gine from starti[...]

45 OPERA TION Cold W eather Operation Internal engine condensation in creases as outside tempe rature s 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[...]

46 OPERA TION Driving Procedures 1. W ear protectiv e ridin g ge ar . See pa ge 18. 2. Perform the pre-ride inspection. See page 43. 3. Place the transmission in P ARK. 4. Mount the vehicle from the left side. 5. Sit upright. Keep your feet o n th e footrests. Keep both hands on the handlebars. 6. S tart the engine and allow it to warm up. 7. Apply[...]

47 OPERA TION T urning the V ehicle 1. Before turning, activate a turn sig- nal to alert others of your inten- tions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. S teer in the direction of the turn, leaning your u pper body to t he inside of the turn while support- ing your weight on th e outer foo[...]

48 OPERA TION Driving with a P assenger Never allow anyone un der 16 years of age to operate this vehicle. Never allow anyone un der 12 years of age to ride as a passenger on this 2-up Quadricycle. Never carry more than o ne passenger on this 2-up Quadricycle. 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably [...]

49 OPERA TION Driving with a P assenger 7. Mount the vehicle from the left side. 8. After the operator is seated, the passenger should mount the vehicle from the left side. NOTE: Allow a passenger to ride only in the approved pa ssenger seat with both feet on the footrests and both hands on the passenger grab ha n- dles at all times. Th e passenger[...]

50 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 2. A void steep hills (15 ° maximum). 3. A void hills with sli ppery or loose surfaces. 4. Keep both feet on the footrests . 5. Shift body weight uph ill. 6. Drive straight u[...]

51 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. A passenger sho uld dism ount first.Th[...]

52 OPERA TION Driving on a Sidehill (Sidehilling) Polaris does not recommend crossing the side of a hill (sidehilling). If sidehilling is unavoidable, follow these precautions: 1. Slow down. 2. If operating in 2X4 mode, make sure the dif ferential is locked () . 3. A void hills with sli ppery or loose surfaces. 4. A void crossing the sides of steep[...]

53 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 31. 2. A void hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4. Drive straight downhill. A void driving downhill at an angle, which can cau[...]

54 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 ascending or descending a hill. See page 31. 3. Lock the hydrau lic parking brake. 4. Leave the tr[...]

55 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. NOTE: A passenger should not remo unt until the vehicle retu rns to level ground. 1 1. Apply the foot brake. 12. W ith the transmission still in forward, start the engine. 13. Squeeze and release the b[...]

56 OPERA TION Driving Through W ater Follow these procedures wh en driving through water: 1. Check water depth and current before cros sing. 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, trave[...]

57 OPERA TION Driving Through W ater If your vehicle becomes fully immersed , and it's impossible to take it to a dealer before star ting it, follow th e steps described on page 100. Have the vehicle serviced by your dealer promptly . Always follow the procedures outlined in this manual for driving through w ater . Never drive through deep or [...]

58 OPERA TION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down b efore driving onto slippery surfaces. 2. Engage 4X4 b efore wheels begin to lose traction. 3. Be alert. 4. W atch the trail. 5. A void quick, sharp turns. 6. Correct a skid by tu[...]

59 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 a s logs, rocks and low branches. 5. Always have a pas senger dismou nt before operating ov er an obsta- cle. Always follow the procedur[...]

60 OPERA TION P arking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Always block the rear wh eels on the downhill side.[...]

61 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. Be aware that a passenge r can obstruct your view . 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 t[...]

62 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to wing cargo improperl y can alte r vehicle handling and may cause loss of control or brake instab ility . Always follow these precautions when hauli ng cargo. • Read and unde rstand the load di stribution warnings listed on the vehicle warning labe ls. • Never exceed the max[...]

63 OPERA TION Hauling Cargo T owing Loads T owing is approved OFF-ROAD ONL Y . Operating a Quadricycle/trailer combination on public roads is prohib ite d. See your Polaris dealer about configuring the vehicle to be certif ied to tow a trailer on-road. Do not tow any trailer on a grade steepe r than 15 ° . If towing a load, reduce rear rack car go[...]

64 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 that was de signed for on-road and of f-road operation. It is required that this spark arrestor re[...]

65 MAINTENANCE P eriodic Maintenance Char t Maintena nce intervals in the follo wing chart are based upon aver age 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 32. [...]

66 MAINTENANCE P eriodic Maintenance Char t Maintenance Chart K e y X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. Perform all services at whichever main tenance interval is reached first. W ARNING Improperly performing the procedure[...]

67 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[...]

68 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[...]

69 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 65. Items not listed in the chart should be lubr icated at the General Lubrication interval. NOTE: The a-arms and upper control arms are lubricated at the facto ry , and no additional lub rication will b[...]

70 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for thi s 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 [...]

71 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Lift the lever lock. Remove the dipstick. W ipe it dry with a cl ean cloth. 4. Reinstall the dipstick completely , but do not lock it. 5. Remove the dipstick and check the oil level on the top side of the dipstick. 6. Maintain the [...]

72 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. Allow it t o idle for 2-3 minutes. 4. S top the engine. 5. Clean the area around the drain plug. 6. Remove the drain plug. Drain the oil into a drain pan. 7. Clean the drain plug. Reinstall the drain [...]

73 MAINTENANCE Engine Oil Oil and Filter Change 9. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclock wise to remove it. 10. Clean the filter sealing area on the crankcase. 1 1. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 12. Install the new oil filter . After the filter[...]

74 MAINTENANCE T ransmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 120 for the p art numbers of Polari s 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[...]

75 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 74. 8. Add the recomme nded oil. See [...]

76 MAINTENANCE F r ont Gearcase (Demand Drive) Fluid Fluid Recommendations Use the recommended fl uid. Use of other fluids may result in improper operation of components. See page 120 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. [...]

77 MAINTENANCE F r ont 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 76. 7. Add the reco mme nded f[...]

78 MAINTENANCE Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the fro nt box. The reservoir cap is yellow . W e recommend the us e of Polaris ADC Fl uid. See page 120 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 . [...]

79 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[...]

80 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[...]

81 MAINTENANCE Cooling System Radiator Coolant 1. Open the front bo x cover . 2. Open the access door . 3. Remove the radia tor pressure cap. 4. If coolant is not visible, slowly add co olan t through the radiator filler neck. 5. Reinstall the pressure cap. 6. Secure the access door and box cover . NOTE: Use of a non-standard pressure cap will not [...]

82 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride . Always maintain brake fluid at th e recommended lev el. Do not overfil l. 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 fluid level may also mean that brake pads are wo rn[...]

83 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[...]

84 MAINTENANCE Brakes The front and rear brakes are hydraulic disc bra kes, activated by apply- ing the foot brake . The handlebar brake is also hydraulic. 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 [...]

85 MAINTENANCE T oe Alignment 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 handlebars in a straight-ahead positi on. 3. T ie a length of string between two stands as shown in the illustration. Position the stands so t[...]

86 MAINTENANCE Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four hand lebar bolts. 3. Adjust the handlebar to the desired height. NOTE: Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right . 4. T orque [...]

87 MAINTENANCE Side P anel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. W ith a firm moti on, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. 5. When reinstalling side panels, align the fasteners and pres s firmly to secure them. F oo[...]

88 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[...]

89 MAINTENANCE Tires Refer to the specifications section beginning on page 1 18 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 3 mm or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operati ons. All service must b[...]

90 MAINTENANCE Tires Wheel Nut T orque Sp ecifications Check the wheel nut torques occasional ly and when they 've been loos- ened for maintenance service. Nut T ype Nut T orque Lug Nut 122 Nm 2-Piece F lange N ut 37 Nm Cast Aluminum Steel 122 Nm 37 Nm[...]

91 MAINTENANCE Tires Always use original eq uipment size and type whe n replacing tires. Install wheels properly . 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 groun[...]

92 MAINTENANCE 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 65. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the seat. 4. Release the air box cover clips. 5. Remove the air box cover . 6. Loosen the hos[...]

93 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 87. 2. Remove the hose clamps from the filter and pull the fil ter 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. Repl[...]

94 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 cente r of the headlight and make a mark on the wall at the[...]

95 MAINTENANCE Lights Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp. 1. Place the transmission in P ARK. 2. Open the front rack cover . 3. Remove the pl[...]

96 MAINTENANCE Lights T aillight Lamp Replacement 1. Place the transmission in PA R K . 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. T est th e lamp for proper operatio n. 6. Reinstall all components in reverse order . F ront T urn Signal Lamp Re[...]

97 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electrical fail- ures, a fuse may need replacement. NOTE: Spare fuses are provided i n a compartment on the top of the access do or . 1. Open the front box cover . 2. Open the access door . 3. Remove the suspect fuse from the fuse panel. Install a new[...]

98 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section begi nni ng o n pag e 1 18 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition after th[...]

99 MAINTENANCE Spark Plugs Spark Plug Removal A hot exhaust system and engine can ca use serious burns. Wear protective gloves when removing a spark plug for inspection. 1. Remove the spark plug cap. 2. Use the spark plug wrench to remove the spark plug. Tu r n t h e p l u g counterclockwise to remove it. 3. Inspect the electrodes for wear and carb[...]

100 MAINTENANCE V ehicle Immersion If your vehi cle has been totally submer ged in water and it's impossible to have it serviced before furthe r operation, perform the following pro- cedure. If the vehicle stops while fully submerge d, major engine damage can resu lt if the machine is not thoroughl y inspected. T ake the vehicle to your dealer[...]

101 MAINTENANCE V ehicle Immersion 4. T urn the ignit ion key past the POSITION LIGHTS position to engage the starter . Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. T orque to specification. See page 98. 7. Attempt to start the engine. If necessary , repeat the drying procedure. 8. Hav[...]

102 MAINTENANCE Spark Arrestor Occasionally , the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Pur ge the spa rk arre stor . 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the arrestor clean-out plug from the bottom of the muf fler . 4. S tart the engine. 5. Quic[...]

103 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 pipe 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.[...]

104 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 be en precision balanced. Any modi fication will cause the system to be out of balance, creating vibrati on and addi tional loads on components. The PVT system rota tes at high [...]

105 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[...]

106 MAINTENANCE Battery Y our vehicle may have either a sealed battery , which requires little maintenance, or a conventional battery . A sealed battery can be identi- fied by its flat covers on the top of the battery . A conventional battery has six filler caps on the top of the battery . Always keep battery terminals and connections free of corro[...]

107 MAINTENANCE Battery Battery Removal 1. Place the transmission in P ARK. 2. Disconnect the battery hold-down strap. 3. Remove the battery cover (if equipped). 4. On conventional batteries, re move the battery vent tube. 5. Disconnect the black (negative) battery cable first. 6. Disconnect the red (positive) battery cable last. 7. Lift the batter[...]

108 MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully char ged. 2. Place the ba tte ry in the batte r y h older . 3. W ith conventional batteries, install the b attery vent tube (seal ed bat- teries do not have a vent tub e). The vent tube must b e free of obstructions and securely installe d. Route the tube away from the[...]

109 MAINTENANCE Battery Battery Fluid (Conventional Battery) Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Add only distilled water . T ap water conta ins minerals th at are harmful to a battery . Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t dama[...]

110 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.[...]

111 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 components. High water pressure may damage components. Polaris recommends washing the vehicle b y ha nd or with a garden hose, using mild soap. Certain products, including ins[...]

112 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 and decals. A v oid direc ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals •B[...]

113 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels expose d to road salt (or salt in th e air in coastal areas) are more su sceptible to corrosio n if not properly cle[...]

114 MAINTENANCE Cleaning and Storage Storage Tips Starting the engi ne during the storage peri od will disturb the prote ctive film created by fogging and damage could occur . Never start the engine during th e storage peri od. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 1 1 1. Stabilize the F uel 1[...]

115 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the flu id levels. Add or change flui ds as recommended in the Periodic Maintenance Char t beginni ng on page 65. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two yea[...]

116 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables a nd lubricat e all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 65. Battery Storage See pages 108-109 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the vehicl[...]

117 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 Quad ricycle to the tr ansport ing unit securely with suitable stra[...]

118 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 800 T ouring Quadricycle Maximum W eight C apacity 568 lbs. (258 kg) (includes operator , passen- ger , cargo, accessories, tongue weight) Dry W eight 795 lbs. (361 kg) Front Rack/S torage Box Capacity 9 0 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Receiver Hitch T ongue Capacity[...]

119 SPECIFICA TIONS Clutching (EBS Models) NOTE: *EBS models require no helix/spring adju stment Sportsman 800 T ouring Quadricycle 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 8.28:1 Drive Ratio, Front 3.82:1 T ires/Pressure, Front 25x8-1[...]

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

121 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 54). Driving at l ow RPM or ground speed (5-1 1 kmh) Drive at a higher speed or use low range more freq uently . Insuffic[...]

122 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[...]

123 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d 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)[...]

124 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 equippe d) W ater is present in fuel Replace wi th fresh rec o mm ended fuel Old or non-recommended fuel Replac [...]

125 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 the Polaris Quadricycle ag ainst 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[...]

126 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF W ARR ANTIE S AND REMEDIES The Polaris l imited warranty e xcludes any fa ilu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper ha ndling. This warranty also doe s not cover any [...]

127 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris d ealer autho- rized to repair Polaris Quadricycles. When requesting warranty se rvice you must present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANS- POR T A TION TO AND FROM THE DEALER IS YO[...]

128 MAINTENANCE L O G Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE KIL OMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

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