Polaris Sportsman 9921822 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 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 , yo ur dealer instructed you on the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y our eligible f[...]

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 Safety W arnings 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. Operat[...]

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 50. • 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. If all forward speed is lost: • Keep body weight uphill. • Apply the brakes. • Lock the parking brake when fully stopped. [...]

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 55. 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 b een placed on the ve hicle for your protec tio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the labe ls on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or g[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 de grees 25 ° . T o prevent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S teering becomes d ifficult. T o prevent loss of c[...]

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 T ire Pressure/Load W arning W ARNIN G Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or deat[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING 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 you are under age 16. 7175374 Rack W arning, Front and Rear W ARNING • DO NOT TO W FROM RACK OR BUMPER. V ehicle damage or tipover may result causing sever[...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse sp eed limit er system . T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button while th e thro ttle is open can cause loss of control, wh ich may resu lt in s[...]

27 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lig h ts on and of f. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. All Wheel Drive Switch See page 35 for all wheel drive information. Throttle Lever Operating an A TV with sticking or impr[...]

28 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, whi ch could cause an accident. Neve r operat e the A TV with a spongy-feeling bra k e lever . Always contact your dealer for service before operati ng th e vehicle. Squeeze the brake lever toward the handlebar to ap ply the front and [...]

29 FEA TURES AND CONTROLS Parking Brake Locking the P arking Brake 1. Place the transmission in gear . 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 .[...]

30 FEA TURES 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 [...]

31 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may cause brake drag or brake l ock-up, which co uld 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 hygro scopic, meaning it rapidly absorbs moisture from the air . The moistu[...]

32 FEA TURES AND CONTROLS Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder . Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handleba rs are straight. 2. V iew the fluid level through the indicat or win- [...]

33 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Always refuel with the engine stopped, and outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel t[...]

34 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehi- cle. H: High Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engine speed above idle or while t[...]

35 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The Al l Wheel Driv e syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive. When in A WD, the demand drive unit will automatically engage any time the rear wheels lose tract[...]

36 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in mile s as well as hours of operation. It also includes a reverse speed limiter function that limits the A TV's speed to approximately 7-9 mph (1 1-14 km[...]

37 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 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2. Engine Hour Display Indicator 3. Speedometer 4[...]

38 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[...]

39 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 oil level on the dipstick. See page 65. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area t [...]

40 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this ve hicle. 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 haus[...]

41 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 ri de. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a local riding club or local officials. Help keep [...]

42 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 ea ch use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 28 76 Brake fluid Ensure pr[...]

43 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 neutral. 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. T urn the fuel valve on. 5. Si[...]

44 OPERA TION S t arting the Engine 9. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the en gin e starts. NOTICE: Operating the vehicle immediate ly after starting could cause engine damage. Allow the engine to warm up for several minutes before operati[...]

45 OPERA TION Driving Procedures 1. W ear a helmet and eye protection.See page 8. 2. Sit uprigh t with both feet on th e footrests and bo th hands 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. Slo[...]

46 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 distance than the inside wheel when turning and the inside tire must slip traction sl ightly . T o turn, steer in the direction of the turn,[...]

47 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trai ls 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 A WD before wheels begin to lose tractio n. NOTICE: Se[...]

48 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. Drive straight uphill. 2. A void steep hills (25 ° maximum) . 3. Always check the terrain care fully before ascending a[...]

49 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 unavoidab le , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

50 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum) . 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the brakes to o firmly may cause the rear [...]

51 OPERA TION Parking on an Incline A void parking on an in cl ine if po ss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Always block the rear wh eels on the downhil l side. 5. T urn the fuel valve off.[...]

52 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. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hi cle, or on the lef[...]

53 OPERA TION Driving Through W ater Y our A TV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures when operating through water: 1. Determine water depths and cu rren t before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void op erating t[...]

54 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[...]

55 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 [...]

56 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[...]

57 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A TV on warning labels and in the specifications section of this manual. Carg o weight should b e evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce s peed an d car go [...]

58 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[...]

59 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[...]

60 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could result i n component failure an d cause an accident, which ma y result in se rious injury o r death. Always have an authorize d Po la ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subj[...]

61 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - W eekly - Inspect; replace as needed X Q Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals; clean; test X F ront gearcase oil (if equipp[...]

62 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) X Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; c[...]

63 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 59. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PL US P erformance Synthetic 2W -50 See page 64. Brake Fluid DOT 4 Only See [...]

64 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 operation[...]

65 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the left front tire. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parkin g brake. 4. Clean away all dirt and debris on the oil tank or in the wheel well area. 5. S tar t the engine. Allow it to idle for 30 seconds. Sto p the engin[...]

66 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beg inning on page 5 9. T o change the oil properly , always drain the oil tank and change the oil filter . If oil contamination (water , mud, metal shavings) is suspected in the engine sump, the sump should also be dra[...]

67 MAINTENANCE Oil and Filter Change 1 1. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 14. Install the new oil filter . After the filter contacts the [...]

68 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 59. Maintain the oil level at the bottom of the fill pl ug hole. See page 109 for the part numbers of Polaris products. The fill plug is located on the left si de of the A TV , under the rear f[...]

69 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill. 7. Reinstall the fill plug. T orque to specification. See page 68 for reco m- mendations.[...]

70 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan u nder the gearcase. 6. Remove the drain plug. Use a 15 mm wrench. 7. Allow the oil to drain completely . 8. Clean and reinstall the[...]

71 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 59. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper opera tion o f compo- nents. See page 109 fo r the part numbe[...]

72 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recomme nded oil as needed to bring the level to the bottom of the fill hole threads. 7. Rei[...]

73 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use an 8mm Allen wrench . 7. Allow the oil to drain complet[...]

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

75 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[...]

76 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

77 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. 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 perfo[...]

78 MAINTENANCE S teering Assembly The steering assemb ly of the A TV 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 top of the side panel and pull it outward to remove it. Footwell [...]

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

80 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Loosen the wheel nuts slightly . W ARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris deale r . 5. Place a suitable stand under the footrest frame to raise the wheel sl[...]

81 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the wheel on the wheel hub with the valve stem toward the ou tside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the vehi cle to the grou nd. 4. T orque the wheel nuts to specification. W ARNING! Loose nuts could cause a tir[...]

82 MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear . 2. Lock the parkin g brake. 3. Remove the seat. 4. Release the air box cover clips, and remove the air box cover . 5. Loosen the clamp and remove the filter . 6. Remove the fabric type pre-fil- ter from the main filter . W a sh the pre-filter in s[...]

83 MAINTENANCE Breather Filter/Hose 1. Remove the left side panel. See page 78. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for cloggin g. Replace a damaged or clogged filter . 3. Check the hoses for cracks, deter[...]

84 MAINTENANCE Light s Headlight 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. 2. Place the transmission in neutral. 3. Lock the parkin g brake. 4. Measure t[...]

85 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 . Headlamp Replacement When servicing a ha logen lamp, don'[...]

86 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifications section begi nni ng o n pag e 1 14 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 plugs.[...]

87 MAINTENANCE Spar k P l ug s S p ark Plug Condition 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 tip[...]

88 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 impossible to take your A TV to a de aler before starting it, follow the steps outlined below . 1. Move the vehicle out of the [...]

89 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. [...]

90 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 bal[...]

91 MAINTENANCE P VT System P VT Drying There m ay be so me ins tances when water is accidently ingested into the PVT system. Use the following instructions to dry it out befo re operating. 1. Move the vehicle out of the water . 2. Remove the P VT drain plug. Use a 17 mm w rench, a f lat sc rew- driver , or the spa rk plug wrenc h. 3. Allow the wate[...]

92 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 [...]

93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parkin g brake. 3. Remove the sp lash shield behind the right front tire. 4. Remove the left side panel to access the battery hold- down bracket. Remove the screw at the bottom rear of the bracket and move the bracket aside. 5. Remove the battery cover . 6. On co[...]

94 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 instructions on page 96 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batte ry in[...]

95 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 maintain a full charge. Polaris r[...]

96 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 r ging. See pa ge 93. 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 specific grav- ity to 1[...]

97 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Measure battery voltage at the starting so lenoi d (near the radiator cap) under the front storage cover . Check the battery voltage with a voltmeter or multimeter . 2. T o rechar ge, carefully attach the RED char ger clamp to the r[...]

98 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 pre ssure may damag e components. Polaris recommend s washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, inc[...]

99 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (n ot 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 (if equipped) • T ransmis[...]

100 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[...]

101 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 coul d 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 98. Stabilize[...]

102 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in th e Periodic Maintenance Chart beg inning on page 5 9. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1.[...]

103 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 59. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV w[...]

104 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prev en t loss during transporting. 7. Always tie the frame of the A TV to [...]

105 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. S pring Adjustment s The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Alwa ys ad just both sides equally . Accessory springs are available through your Polaris dea ler [...]

106 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 li mited steeri ng or loosening of the handlebars, resulti ng in lo ss of control and serious injury or death. Follo w the adjustment procedures e[...]

107 ADJUSTMENTS Carburetor Y our Polaris A TV is cali brated at the factor y for optimal performa nce at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power fo r ea[...]

108 ADJUSTMENTS 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 slide it far enough to expose th e end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

109 POLARIS PRODUCTS Pa r t Number Desc ription Engine L ubricant 2870791 Fogging Oil (12 oz . Aerosol) 2876244 PS-4 PLUS P erformance Syn thetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Syn thetic 2W -50 4-Cycle Oil (gal .) Gearcase / T ra nsmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium A[...]

110 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range (if equipped). Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 52). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range[...]

111 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Blown fuse Replace fuse 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 Solut[...]

112 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 Idle set too low Adjust idle speed Possible Cause Solut[...]

113 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 Inspect and replace W ater is present in fuel Replace with new fuel Overuse of choke Ins pect, cl ea n a nd/or replace spark plugs Foule[...]

114 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 400 HO 4X4 Maximum W eight Capacity 385 lbs. (175 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 598 lbs. (271 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.2 qts. (2 l) T ransmission Oil 20.3 oz. (600 ml) Demand Drive [...]

115 SPECIFICA TIONS Jetting Chart Clutching Ch art Sportsman 400 HO 4X4 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (H/N/R) Drive Ratio, Fron t 3 .6:1 Drive Ratio, Final 15.18:1 T ires/Pressure Front 24x8-12 / 5 psi (34.5 KPa) Rear 24x1 1-12 / 5 psi ( 34.5 KPa) Front Suspension MacPherson strut with 7[...]

116 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[...]

117 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 [...]

118 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 al low limi- tations on[...]

119 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[...]

120 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[...]

121 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 ehicle (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 th[...]

122 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[...]

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