Polaris Sportsman 9922237 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 [...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922237 Rev 02 Printed in USA W ARNING Improper vehicle use can result in SEVERE INJUR Y or DEA TH. LOCA TE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS. AL W [...]

1 WELCOME Thank you for purch asing a Polaris vehicle, 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[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered trademark s of Polaris Industries Inc. Copyright 2009 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 disc[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 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 zard. W ARN ING A W ARNING indi cates a hazar[...]

5 INTRODUCTION Failure to hee d the w arnings and safety precautions con tained 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 maneuve[...]

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 existi ng keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available [...]

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 caution whenever han dling gasoline. • Always refuel with the en gine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refuelin[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without 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). Carrying a Passenger Do n[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewal ks, paths, p arking lots 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 T V on pavement. A TV tires are design ed for off-road use. If it's u[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing even one hand or foot can reduce ability to control the ve hicle or could cause loss of balance and ejecti on from the A TV . If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving part s and lead to accident or in[...]

15 SAFETY Safety W arnings Improper Hill Climbing Improper hill cl imbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as describe d in the owner's manual. See page 54. Descending Hill s Impr operly Improperly descending a hill could ca use loss of control or overturn. Always follow proper procedu[...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or improperl 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: • Lean forward to keep body we ight uphill . A passenger should also lean uphill. • Apply the s[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessi vely rough, sli ppery or loose terrain until you've learned and practiced the skills nece ssary to [...]

18 SAFETY Safety W arnings Improper T ire Maintenance Operating this A TV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your A TV . Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating O[...]

19 SAFETY Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast- flowing water could cause the tires to float, causing loss of con trol or over turn. Avoid operating the A T V through dee p or fast-flowing water . If it's unavoidabl e to enter water that exceeds the recommended maximum depth (see page 59): • [...]

20 SAFETY Safety W arnings Operating on Froz en Bodies of Wa t e r Operating on frozen bodies of water may result in serious injury or death if the A TV and/or riders fall through the ice. Never operate the A TV on a frozen body of water . Poor V i sibility Operating the A TV in darkness or inclement weather could result in a collision or accident,[...]

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 decals hav e been placed on t he A TV for your p rotection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manu al dif fer from the decals on your A TV , always read and follow the instruc tions of the decals on the A TV . If an information[...]

23 SAFETY Safety Labels and Locations General W arning/Discretionary W arning W ARNING Improper A TV use can result in SEVERE INJURY or DEA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND P ASSENGER NEVER USE ON PUBLIC ROADS NEVER CARR Y MORE THAN 1 P ASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper [...]

24 SAFETY Safety Labels and Locations Passenger Safety W arning W ARNIN G P ASSENGER SAFETY T o reduce the risk of SEVERE INJURY or DEA T H NEVER CARR Y MORE THAN ONE P ASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footre sts and securely gr asp hand hold s. THE P ASSENGER MUST AL W A YS [...]

25 SAFETY Safety Labels and Locations Rack W arning W ARNING 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: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7172572 Clutch Cover W arning W ARNING • Moving part s hazard under belt-clutch gu ard[...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional wheel speed while backin g, depress the override switch. W ARNING! Activating the override switch while the throttle is open can cause loss of control, wh ich may resu lt in seri ous injury o r death. A[...]

27 FEA TURES AND CONTROLS Switches Engine S top Switch Move the stop switch eith er left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electrical po wer to the vehicle, including lights. Main Key Switch Use the main[...]

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

29 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 th e A TV with a spongy-fee ling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handlebar to ap ply the front and r[...]

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

31 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lo ck, squeeze and release the brake lever [...]

32 FEA 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 back 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 s[...]

33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 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 e ngine speed ab[...]

34 FEA TURES AND CONTROLS Passenger Seat Always make sure the passenger seat is installed and securely latched before operating with a passenger . T est the seat latch by attempting to pull the seat upward. If the lock-out is not working pr operly , do not allo w a passenger to ride the vehicle. See your Polaris dealer for service. T o remove the s[...]

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

36 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmissi on. In addition to showing vehicle speed, the speedometer n eedle flashes when a warning condition exists. The instrument cluster meas ures dist ance in miles as well as hours of operation. It also[...]

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

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

39 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[...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Scr een V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Screen The gauge indicates wheth er or not current is flowing throu gh the A WD coil (only on models with swit[...]

41 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 oggle t o the serv ic e interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Ce[...]

42 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 hours[...]

43 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

44 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 T V before each use to make sure it's in safe operating condition. Item Remarks Page Passenger sea t latch Ensure latch is secure 34 Brake system/lever travel Ensu[...]

45 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle . Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Engine ex haust fumes are poisonous. Never start the eng[...]

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

47 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit [...]

48 OPERA TION S t arting the Engine 1 1. 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 gine starts . NOTICE: Operating the vehicle immediate ly after st a rting could cause engi ne damage. Allow the engine to warm up for several minutes before op[...]

49 OPERA TION Driving Procedures 1. W ear protective riding gear . See page 8. 2. Perform the pre-ride inspection. See page 44. 3. Place the transmission in P ARK. 4. Lock the parkin g brake. 5. Mount the vehicle from the left side. 6. Sit uprigh t with both feet on th e footrests and bo th hands on the handlebars. 7. S tart the engine and allow it[...]

50 OPERA TION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up A TV . Make sure any p assenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you ha ve at least two hours of driving experience with this vehicle. 3. Make sure t[...]

51 OPERA TION Driving with a Passenger 1 1. Ride to the ability of your passeng er , instead of to your own ability . A void unexpected or aggressive mane uvers that could cause a pa s- senger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 55. 13. A pas senger sh ould alwa ys be seat ed in the passenger se[...]

52 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 outside w heel mus t trav el a greater d istance than the inside wheel when turning, and the inside tire must slip traction slightly . 1. Slow down. 2. Never turn quickly when carrying a passenge[...]

53 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 precautions: 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: Sev[...]

54 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 (15 ° maximum ). 3. Always check the terrain care fully before ascending a[...]

55 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. [...]

56 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. 8 ft. (2.4 m)[...]

57 OPERA TION T urning Around on a Hill (K-T urn) 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. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the ve hi- cle, or on the left if th[...]

58 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (15 ° maximum ). 2. Always check the terrain carefully before descending a hill. 3. Always descend a hill with the tr ansmission in forward gear . Do not descend a hill with the tr ansmission in neutral. 4. Slow do wn. Never travel down a hil l at[...]

59 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both ba nks have gradual inclines. 3. A void operatin g throug[...]

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

61 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or peop le behind the vehi cle. Be aware that a passenger can obstruct your view . 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 th[...]

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

63 OPERA TION Hauling Cargo Overloading the vehicle or ca rrying or tow 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: Never carry cargo on the rear rack when operating the A TV in the 2-up mod[...]

64 OPERA TION Hauling Cargo Never exceed the weight capacitie s specified for your A TV on warning labels and in the specifications sec- tion of this manual. 1. Cargo weight should be evenly distributed (1/3 on th e front rack and 2/3 on the rear rack) and moun ted as low a s possible . 2. When operating o ver rough or hilly terrain, re duce speed [...]

65 OPERA TION Hauling Cargo T owing Loads Always attach a towed load to the hitch point. Remove the hitch from the A TV when not towing a trailer . If towing a load, reduce rear rack car go weight by the amount o f tongue weight. • The comb ination of rear rack car go weight an d tongue weight must not exceed the rear rack capacity . • The tota[...]

66 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[...]

67 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 intenanc e chart. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

68 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a Q coul d result in component failure an d cause an accident, which ma y result in se rious injury o r death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles subject[...]

69 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 Recoil housing (if applicable) - Weekly - Drain water as needed, check often if operating in wet conditions X Q Brake pad wear 10 H Monthly 100 (160) Inspe[...]

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

71 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and upper control arms are lubricated at the factory , and no additional lubrication will be neede[...]

72 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Pola ris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil desi gned to provide the ultimate in lubrication performance and pro tection. See page 12 6 for the part num- bers of Po[...]

73 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the A TV . Tip : A rising oil le vel between checks in cool weather driving can indi cate contaminants such as gas or mois- ture collectin g in the crankcase. If the oil level is over the full/sa fe mark, change the oil immediately . 1. Position the vehi[...]

74 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beg inning on page 6 7. 1. Position the vehicle on a level surface. 2. S tart the engine. All ow it to idle for two to three minutes. 3. S top the engine. 4. Clean the area around the drain plug. 5. Place a d[...]

75 MAINTENANCE Engine Oil Oil and Filter Change 12. Place shop towels benea th the oil filter . Using an oil filter wrench, turn the filter counter -clockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase. 14. Lubricate t[...]

76 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must b e performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line&apos[...]

77 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 67. Maintain the oil level at the bottom of the fill pl ug hole threads. W e recomme nd the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 126 for the part numbers of Polaris[...]

78 MAINTENANCE T ransmission Oil T ransmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drai n plug. Allow the oil to drain completely . 4. Clean and reinstall the drain plug. T orque to 20-25 ft. lbs. (27-34 Nm). 5. Add 32 oz. (9 48 ml) of the recommended oil. 6. Reinstall the fill plug. T orque to[...]

79 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginn ing on page 67. W e rec- ommend the u se of Demand Dr ive Plus Fluid. Use of other fluids may result in improper operation of comp on ents. See page 126 for the part numbers of Pola[...]

80 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recomme nded dem and driv e fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. T orque to 8-10 ft. lbs. (1 1-14 Nm). Fluid Change 1[...]

81 MAINTENANCE Cooling System The engine coolant level is controlle d, or maintained, by the recovery system. The recovery sy stem compon ents are t he recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (hea ted) excess coolant is forced out of the [...]

82 MAINTENANCE Cooling System Recovery Bottle Coolan t The recovery bottle is located on the left side of the vehicle. 1. Remove the left side panel. See page 86. 2. Maintain the coolant level between the minimum and maximum marks on the bot- tle (when the fluid is cool). 3. Add coolant as needed. Recove ry Bottle[...]

83 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[...]

84 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handleba r . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s. If the fluid leve l is low and the diaphragm is not extended, a leak is li[...]

85 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 alignment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perfor[...]

86 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 rear of the side panel near the rea r cab. W ith a firm motion, p[...]

87 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. Alway[...]

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

89 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre- filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main[...]

90 MAINTENANCE Breather Filter/Hose The breather filter is on the hose th at runs between the engine and air box. 1. Remove the left side pan el. 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 clo[...]

91 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replaceme nt. Spare fuses are provided in a com- partment on the top of th e access door . 1. Open the front box cover and pull open the access door . 2. Remove the suspec t fuse from the fuse panel. If the fuse is [...]

92 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal opera tion. Clean head- lights frequently and replace burned out headlamps promptly . Always make sure lights are adjusted properly for best visib ility . Headlight Lamp Replacement When servicing a halogen [...]

93 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in P ARK. 2. Measure the distance from the floo r to the ce[...]

94 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedome ter harnesses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a s[...]

95 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headla mp. 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harness clock- wise to secure th[...]

96 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifi cations section beginn ing on page 124 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p[...]

97 MAINTENANCE Spar k P l ug s S p ark Plug Inspection Normal S p ark 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 t[...]

98 MAINTENANCE Camber and Caster The camber and caster are non-adjust- able. Rear S pring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Tip : Accessory springs are avai lable through your Polaris dealer . Adjuster[...]

99 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adjustment of the hand leba rs or incorrect torquing of the adjuster block tightenin g bolts can caus e limited steering or loosenin g of the handlebars, resulti ng in loss of control and serious injury or death. Follo w the adjustment procedures exact[...]

100 MAINTENANCE Carburetor Y our Polaris A TV is calibrate d at the factory for optimal performan ce 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 (180 0 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea [...]

101 MAINTENANCE 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"[...]

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

103 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings 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. [...]

104 MAINTENANCE P V T 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 b[...]

105 MAINTENANCE P V T System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed [...]

106 MAINTENANCE P V T System When T o Use Low Range and High Range P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall t[...]

107 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removing 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 [...]

108 MAINTENANCE Battery Battery Removal 1. Remove the battery ho ld-down strap. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not to tip a conventi[...]

109 MAINTENANCE Battery Battery Inst allation 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 hinder vehicle performance. Follow the battery charging instructio ns on page 1 1 1 befo re installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery[...]

110 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 ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha rge as needed to mainta in a full char ge. Tip : Po[...]

111 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prev ent damage from leak- ing or spilled ele ctrolyte during cha rging. See page 108. 2. Char ge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the spec ific grav- ity to 1[...]

112 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. S t ate of Charge V oltage Action Charge Ti me (Using constant current charger @ st andard amp s specifi ed on top o f batter y) 100% 12.8-13.0 vol ts None, check at 3 mos. from date of manufacture None required[...]

113 MAINTENANCE Cleaning and S torage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, inclu[...]

114 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals •[...]

115 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[...]

116 MAINTENANCE Cleaning and S torage Sto r a g e 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 1 1 3. S t abiliz[...]

117 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the flu id levels. Add or chan ge fluids as recommen ded in the Periodic Maintenance Char t beginni ng on page 6 7. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid looks [...]

118 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cables and lubric ate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 67. Battery Storage See pages 1 10-1 1 1 for storag e and char ging procedures. S torage Area/Covers Set the tire pressure and safely suppor t the[...]

119 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in PA R K . 3. Lock the parkin g brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the f[...]

120 TROUBLESHOOTING Drive Belt W ear/Burn Possible Ca use Solution Driving onto a picku p or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 56). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher sp eed or us e low range more frequ[...]

121 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Ca use Solution Out of fuel Refuel,[...]

122 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Ca use Solution Poor quality or low octane fu el Replace w ith recomme nded fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Ca use Solution Fouled or defective spark plu[...]

123 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Ca use 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 Overuse of choke Ins pect, cl ean a nd/or replace spark plugs W ater is present in fuel Replace with new fuel Foule[...]

124 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN T ouring 500 HO Maximum W eight Capacity 705 lbs. ( 320 kg) (includes operator , passenger , cargo, accessories) Dry W eight 770 lbs. (349 kg) (base model) Front Rack/S torage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Receiver Hitch T ongue Capacity 120 lbs. (55 [...]

125 SPECIFICA TIONS Clutching (EBS Models) *EBS models require no helix/spring adjustment Jetting Chart SPORTSMAN T ouring 500 HO Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Front Suspension MacPherson st rut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 8.75" (22 cm) tr avel T ransmission Automat[...]

126 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engin e Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603 Premium [...]

127 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elepho ne 763-542-0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

128 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 co[...]

129 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 [...]

130 W ARRANTY LIMIT A TIONS OF W ARRANT IES AND REMEDIE S This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface im perfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude co mpensati[...]

131 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 AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER D ISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARRANTY . Some states do not allow limi- tations on h[...]

132 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 hav e received authorization for export from Polaris Industries. De[...]

133 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 ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

134 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited war ranty is in addition t o the Polaris sta ndard limited wa rranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified veh icle is designed, built and equipped so it conforms with applica- ble U.S. Environ[...]

135 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited war ranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SE T FOR TH IN THIS LIMITED W ARRANTY AR E THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

136 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehi- cle is serviced. This will provid e you and future owners with an accurate log of maintenance and services performed. DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS[...]

137 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS[...]

138 INDEX A Accessories . . . . . . . . . . . . . . . . . . 118 Air Filt er . . . . . . . . . . . . . . . . . . . . . 89 All Wheel Drive Syst em . . . . . . . . . 35 Auxiliary Foo t Brake . . . . . . . . . . . . 84 AWD Switch . . . . . . . . . . . . . . . 27, 35 B Battery . . . . . . . . . . . . . . . . . . 107-112 Charging (Conventional) . . . . 1[...]

139 INDEX F Fluid, Brake . . . . . . . . . . . . . . . . . . . 30 Fluid, Demand Drive . . . . . . . . . 79-80 Fluid Change, Demand Drive . . . . . . 80 Fluid Level, B rake . . . . . . . . . . . 30, 32 Fluid Level, De mand Drive . . . . . . . 80 Foot Brake, Auxilia ry . . . . . . . . . . . . 32 Footwell Removal . . . . . . . . . . . . . . . 86 Fuel [...]

140 INDEX P Parking Brake . . . . . . . . . . . . . . . . . 31 Parking on an Incl ine . . . . . . . . . . . . 62 Passenger Seat . . . . . . . . . . . . . . . . . 34 Periodic Maintenance Chart . . . . 67-70 Polaris Pro duct List . . . . . . . . . . . . 126 Polishing the Vehicle . . . . . . . . . . . 114 Pre-Ride Checklist . . . . . . . . . . . . . .[...]

141 INDEX S Switches . . . . . . . . . . . . . . . . . . . 26-27 AWD Switch . . . . . . . . . . . . 27, 35 Engine Stop Switch . . . . . . . . . . 27 Headlight Swit ch . . . . . . . . . . . . 27 Main Key Swi tch . . . . . . . . . . . 27 Mode Swit ch . . . . . . . . . . . . . . . 26 Reverse Override Switch . . . . . 26 T Taillight La mp Replacem ent [...]