Polaris Sportsman 9922249 manual

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A card cont aining import ant A TV safety information should be atta ched to the owner's ma nual on the next p age. If you cannot locate th is card, or if it has been removed, p lease call 1 -800-342- 3764 for assistance. WA R N I N G The eng ine exhaust fr om this produ ct contains chemic als known to the S tate o f California to cause ca nce[...]

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

W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of losing contr ol. AL [...]

1 WELCOME Thank you for purch asing a Polaris vehicle, an d welcome to our world- wide family of Polaris owners. W e proud ly 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 f[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered tra demarks of Polari s 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 dis[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 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 h e manual. The safety ale rt symbol indicates a potentia l personal injury haza rd. W ARNING A W ARNING indicate s a hazar[...]

5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained in thi s manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es 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 existing keys. The ignition switch[...]

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

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 chance of in jury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

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

10 SAFETY Failure to operate the A TV properly can re sul t 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 the OPERA TION section of the owner ’ s manual fo r proper operating proce dures. Operating Without Instru[...]

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

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). Using Alcohol or Drugs Op[...]

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 could result in loss of control and accident or overturn. Avoid operating the A TV on p avemen t. A TV tires are design ed for off-road use. If it's un[...]

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 operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as descri bed in the owner 's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 55. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling ba ckwards or improperly 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 coul d 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 result in a collision with an obstacle or person. Always follow prope r operating procedures as outli ned in this manual. See page 59. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When it's safe to proc[...]

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 caution and always follow proper ope rating proce dures as outlined i[...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo imprope rly may cause changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load cap acity for this A TV . • Cargo should b e properl y distributed and securely attached. • Reduce speed when carrying carg[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A TV can result in an 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 icle[...]

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

23 SAFETY Safety Labels and Locations T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 515 lbs. (234 kg) 7175643 + + T ire Pressure/Load[...]

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

25 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving part s ha zard under belt-clutch gu ard. T o prevent serious i njury , do not operate vehicle with gu ard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in seriou s injury or [...]

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 backing, release the throttle and depress the override button. W ARNING! Pressing the override button while the throttle is ope n can cause loss of control, wh ich may result in seri o[...]

27 FEA TURES AND CONTROLS Switches Engine S top Switch Move the stop switch either 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 electri- cal power to the vehicle, including lights. Main Key Switch Use the main[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr o perly 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 [...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spong y-feeling brake lever . Always contact your dealer for service before opera ting the vehicle. Squeeze the brake lever toward the handlebar to ap ply the front and rea[...]

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 injury or death. Ne ver back down a hill. Use caution when applying the a uxiliary brak e. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may sk[...]

33 FEA TURES AND CONTROLS 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 to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with ethanol content gr eater th[...]

34 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wh eel Drive system 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 u[...]

35 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. In additi on to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes [...]

36 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[...]

37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center S t andard Modes Use the MODE button to toggle thro ugh the mode options. Th e 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 records the m iles travel ed by the A TV . T [...]

38 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 mov e- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the[...]

39 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 a chometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Sc reen The gauge indicates whether or not current is flowing through the all- wheel-drive coil. This screen [...]

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

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

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

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Descript ion 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System V oltage Low 31 System V oltage High 36 Ignition Coil A Prim/Sec Cir[...]

44 OPERA TION Failure to operate the A TV properly can re sul t 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 o[...]

45 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 70. Add oil if necessary to maintain the level betwee n the safe and add marks. 3. Drive slowly at first. Select an op en a[...]

46 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 Brake system/lever travel Ensure proper operation 29 80 Brake fluid Ensure pro[...]

47 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 vehicle. 3. Never carry a passenger on this A TV . 4. Engine ex haust[...]

48 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 loca l riding club or local officials. Help keep[...]

49 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 transmis sion is in gear and the brake is not engaged. 4. Sit on the vehicle and move the [...]

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

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

52 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these 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 befor e wheels begin to lose t raction. NOTICE: Sev[...]

53 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[...]

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

55 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 b rakes too firmly may cause the rear [...]

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. 1. S top and lock the parking brake wh ile keeping body weight uphil l. 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 le[...]

57 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recom- mended dep th equal to the b ot- tom of the footrests. Follow these procedures when operat- ing throug h water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks hav e gradual inclines. 3. A void operatin[...]

58 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 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 unfamiliar[...]

59 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 [...]

60 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly can al ter vehicle 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 CARGO[...]

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

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.[...]

63 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 a rrestor that was tested and qual[...]

64 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 intenance chart. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the n[...]

65 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedure s marked with a  could result i n component failure and cause an accid ent, wh ich ma y result in seri ous injury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles subj[...]

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

67 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.  E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary E Throttle Body Intake Duct 50 H 6 M [...]

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

69 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 64. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be needed[...]

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

71 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. S tart the engine. Allow it to warm up at idle for two to three min- utes. 3. S top th[...]

72 MAINTENANCE Engine Oil Oil and Filter Change 1 1. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o -ring is in good condition. 12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn. 13. Remov e the dipst[...]

73 MAINTENANCE T ransmission Oil Always check and change the transmission oil at t he intervals outlined in the Periodic Mainte- nance Chart beginning o n page 64. Maintain the oil le vel at the bottom of the fill plug hole. The fill plug is located on the right side of the A T V behind the footwe ll. The drain plug is located on the bottom left si[...]

74 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 64. W e rec- ommend the u se of Demand Driv e Plus Fluid. Use of othe r fluids may result in improper operation of comp on ents. See page 120 for the part numbers of Pol[...]

75 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. Remove the drain plug. Allow the fluid to drain completely . 3. Clean and reinstall the drain plug . T orque to 1 1 ft. lbs. (15 Nm). 4. Add the recomme nded fluid. See [...]

76 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill. The fill plug is located on the rear of the gearcase. The drain plug is[...]

77 MAINTENANCE Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 3. Remove the drain plug. Allow the oil to drain completely . 4. Clean and reinstall the drain plug with a new sea ling washer . T orque to 14 ft. lbs. (19 Nm). 5. Remove the fill plug. Add 5 oz. (150 ml) of the recomme[...]

78 MAINTENANCE Cooling System The engin e coolant level is controlled, or maintai n ed, 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[...]

79 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[...]

80 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[...]

81 MAINTENANCE T o e Alignm ent Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/ 4" (3-6 mm) toe o u t. W ARNING! Severe injury or death can resul t from improper toe alignment and adjustment. Do not atte mpt to adjust tie rod alignment. Al l tie rod a djustments should be [...]

82 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear S pring The rear shoc k absorber sp ring is adjuste d by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Access ory springs are available through your Polaris dealer . Handlebars The handlebars can be adjusted for ride[...]

83 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and s[...]

84 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be checked period ically for loose nuts and bo lts. If loose nuts and bolts are fo und, see your Polaris dealer for service before ope rating the vehicle. 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, pul[...]

85 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly inflated tires, no n-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[...]

86 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 [...]

87 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 [...]

88 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience othe r electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the top of the access door . 1. Open the front box cov[...]

89 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 lamp s promptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a ha logen lamp, don[...]

90 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[...]

91 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or downward . 1. Loosen the phillips screw located at the rea r of the headlamp . 2. T ilt the headlamp upward or downward. 3. T ighten the screw . Phillips Screw[...]

92 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[...]

93 MAINTENANCE Light s Lower Headlamp Replacement 1. T u rn 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 u rn the headlight harness clock- wise to secure [...]

94 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifications section begi nning on page 1 18 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 [...]

95 MAINTENANCE Spar k P l u g 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 [...]

96 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 h e steps outlined below . 1. Move the A TV to dry land or[...]

97 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 protection and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging. Ne[...]

98 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[...]

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

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

101 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 [...]

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

103 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 105 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in[...]

104 MAINTENANCE Battery Batter y Stor 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 torage and recha r ge as needed to mainta in a full charge. Polaris re[...]

105 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 102. 2. Char ge the battery with a charging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.[...]

106 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 amps specifi ed on top o f batter y) 100% 12.8-13.0 vol ts Non e, check at 3 mos. from date of manufacture None required[...]

107 MAINTENANCE Cleaning and S torage W ash ing 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, incl[...]

108 MAINTENANCE Cleaning and S torage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or co[...]

109 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 ye ars. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C lean c[...]

110 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S tarting the engin e during the storage period will disturb 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 repa irs and then clea n the vehicle a s recommended. See page 107. S t [...]

111 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommende d in the Periodic Maintenance Char t beginni ng on page 64. • Demand drive unit (front gearcase) • Rear gearcase • T ra nsmission • Brake fluid (change every two years and any time the fluid looks dark or co[...]

112 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cabl es and lu bricate all areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 64. Battery Maintenance Remove the battery and recharge it as outlined on page 105. S tore the battery in a cool, dry place. S torage Area/Cove[...]

113 MAINTENANCE T ransporting the V ehicle 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, oil cap and seat. 5. Always tie the frame of the A T V to the transporting unit securely with suitable straps or ro pe. Do not attach tie str[...]

114 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause 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 freque[...]

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

116 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 recommen ded fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs[...]

117 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 wi th new fuel Fouled or defective spark plugs Inspec t, clean and/or replace spar[...]

118 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN 800 EFI Maximum W eigh t Capacity 515 lbs. (234 kg) Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Rear Gearcase Oil Capacity 5 oz. (150 ml) Demand Drive Fluid Ca pacity 9 oz. (265 ml) T ransmission Oil Capa city 15 oz. (450 ml) Fr[...]

119 SPECIFICA TIONS Clutching SPORTSMAN 800 EFI T ransm ission Automatic PVT wi th E-Z Shift H/L/N/ R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5 .1 1:1 Gear Reduction, High 2.88:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 T ires/Pressure, Front 26x8-12 / 5 psi (34.5 KPa) T ires/Pressure, Rear 26x1 1-12 / 5 psi (34.5 KPa) Brake[...]

120 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Perfo rmance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2 W -50 4-Cycle Oil (gal.) Gearcase / T ransmission Lu bricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603 Premium AG[...]

121 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 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 /[...]

122 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all comp onents 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[...]

123 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES Warranty does not apply to pa rts exposed to friction surfaces, stresses, environmental conditions and/or contaminat ion for which they were not designed or not intended, including but not limited to the following ite ms: W arranty applies to the product only an d does not allow for cov e rag[...]

124 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES This warranty does not cover the use of unauthor ized lubricants, chemical s, or fuels that are not compatibl e with the A TV . The exclusive r emedy for breach of this warranty sha ll be, at Polaris' exclusive option, repair or replacement of a ny defective materials, or com- ponents or[...]

125 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIF ICALL 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 LOCA - TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. D[...]

126 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 [...]

127 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warranty is in addition t o the Polaris standard limite d warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.S. Environme[...]

128 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem e dy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN THIS LI MITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF [...]

129 MAINTENANCE LOG Present this section of your ma nual 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 SER VICE PERFORMED / C OMMENTS[...]

130 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / C OMMENTS[...]

131 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / C OMMENTS[...]

132 INDEX A Accessories . . . . . . . . . . . . . . . . . . 112 Air Filt er . . . . . . . . . . . . . . . . . . . . . 87 All Wheel Drive Syst em . . . . . . . . . 34 Auxiliary Foo t Brake . . . . . . . . . . . . 80 AWD Switch . . . . . . . . . . . . . . . 26, 34 B Battery . . . . . . . . . . . . . . . . . . 101-106 Charging (Conventional) . . . . .[...]

133 INDEX H Hand Brake . . . . . . . . . . . . . . . . . . . . 80 Handlebar Adjust ment . . . . . . . . . . . 82 Hauling Cargo . . . . . . . . . . . . . . . 60-61 Headlight Housing Replacement . . . 92 Headlight La mp Replaceme nt . . . . . 89 Headlight S witch . . . . . . . . . . . . . . . . 27 Helmet . . . . . . . . . . . . . . . . . . . . . . . [...]

134 INDEX S Safety Warnings . . . . . . . . . . . . . . 11-21 Service Inte rval Programming . . . . . 40 Severe Use . . . . . . . . . . . . . . . . . . . . 64 Side Panel Removal . . . . . . . . . . . . . 84 Sidehilling . . . . . . . . . . . . . . . . . . . . 54 Signal W ords . . . . . . . . . . . . . . . . . . . 4 Spark Arrestor . . . . . . . . . .[...]