Polaris Sportsman 9921309 manual

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For your nearest P olaris dealer , call 1-800-POL ARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 P art No. 9921309 Rev 02 Printed in USA P antone 626 cvc Improper vehicle use can result in SEVERE INJUR Y or DEA TH. NEVER: S Operate on public roads. A collision can occur with another[...]

W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth defects or other reproductive harm.[...]

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 exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a ll u[...]

2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some minor discrep-[...]

3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F e atures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emission Control Systems . . . . . . . . . . . . .[...]

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5 KNOW Y OUR VEHICLE As the operator of the vehicle, yo u are responsible for yo ur personal safety , the safety of others, and the protection of our enviro nment. Read and understand your o wner's manual, which includes valuable info rma- tion abou t all aspects of your vehicle, incl uding safe operating proce- dures. V ehicle Identification [...]

6 SAFETY Safety Decals and Locations W arning decals have been placed on the A TV for your protection. Read and follow the instructions of the de cals on the A TV caref ully . If any of the decals depicted in this manual dif fer from the decals on your A TV , always read and follow the instructions of the decals on the A TV . If any decal becomes i[...]

7 SAFETY Safety Decals and Locations Tire Pressure/Load W arning WARNING IMPROPER TIRE PRES SURE OR OVER L OADING can cause loss of control resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KP a): FRONT 5 (3 4.5) CENTER 5 (34 .5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACITY 1090 LBS. (494 kg) INCLUDES WEIGHT OF OPERA TOR , CARGO AND ACCESSORIES[...]

8 SAFETY Safety Decals and Locations Age 16 W arning WARNING Operating this A T V if you are under th e age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. Container/No P assenger W arning WARNING Remove flammable containers from box before refueling. WARNING • P assengers can be thro wn of[...]

9 SAFETY Safety Decals and Locations All Wheel Drive Switch Do not push switch to engage AWD if th e rear wheels are spi nning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. Hitch Capacity Label TRAILER MAX WEIGHT : 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15 ° GRADE HITCH MAX. VERTICAL WEIGH [...]

10 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 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[...]

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

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WA R NI N G F ailure to fo llow the warnings contained in this manual can result in severe injury or death. A Po laris A TV is n ot a toy and can be hazardous to operate. This vehicle handles differently th[...]

13 SAFETY Operator Safety Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchased your new A TV , your deal er instructed you on the authorized A TV RiderCourse sm available to yo u and your e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y[...]

14 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The sa fety alert symbol , on your vehicl e or in this manual, alerts you to the potential for in jur[...]

15 SAFETY Operator Safety • Read this manual and all labels carefully , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV RiderCourse sm . Conta ct A TV Enrollment Express a[...]

16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as de scribed in this manual. Practice turning at low speeds befo re attempting t[...]

17 SAFETY Operator Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedu res when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. On slip pery surfaces like ice, travel slowly[...]

18 SAFETY Operator Safety Equipment Modifications W e are concerned for th e safety of our customers and for the general public. Therefore, we strongly reco mmend that consumers do not install on a Polaris A TV any equipment that may increase the speed or power of the vehicle, or make any other m odifications to the vehicle for these purposes. Any [...]

19 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Opera ting this A TV without pr oper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the A TV properly in different situ ations and on different types of terrain . HOW TO A VOID THE HAZAR D Beginning and inexperi enced oper[...]

20 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Carrying a pa ssenger on an A TV . WHA T CAN HAPPEN Carrying a pa ssenger greatl y reduces the operator's abil ity to balance and control the A TV , which could cause a n accident and injury to the opera tor and/or pa ssenger . A passenger riding on a ra ck or in the cargo bed can fall fro[...]

21 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZAR D Never operate the A TV on any public street, road or highway , inclu ding dirt and gravel roads. In many states it's illegal to operate A TVs on[...]

22 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating the A T V after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator jud gment. Reaction time may be slower and operator bala nce and perception co uld be affected. Consuming alcohol and/or drugs before or while operati ng an[...]

23 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts in creases the chance of an accident, including an overturn. HOW TO A VOID THE HAZAR D Never attempt jumps or other stunts. Avoid exhibition driving. WA R NI N G POTENTIAL HAZARD F ailure to inspe ct the A TV before operating[...]

24 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Removing hands from the handleba rs or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce abili ty to control th e vehicle or could cause loss of balance and ejection from the A TV . If the operator's foot is not fi rmly planted on the foot[...]

25 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD F ailure to use extra caution when operating on excessivel y rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on e xcessively rough, slippery or loose terrain could cause loss of traction or lo ss of control, which could result in an accident or overturn. HOW TO A VOID THE HAZAR D D[...]

26 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating on e xcessively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZAR D Never operate on hills too steep for the A TV or fo r your abilities. Never operate the A TV on hills steeper than 15 degrees. WA R NI N G POTENTIAL HAZARD Climbing hills improperly . WHA[...]

27 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZAR D Always follow proper procedures for traveling down hills as describ ed in the owner's manual. NOTE: A special tech nique is required when braki[...]

28 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting whil e climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZAR D Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the service brakes. Lock the parking brak[...]

29 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Improperly operating over obstacl es. WHA T CAN HAPPEN Operati ng over obstacle s could cause loss of cont rol or overturn. HOW TO A VOID THE HAZAR D Before operating in a ne w area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen tre es when possible. If unav[...]

30 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating the A T V through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO A VOID THE HAZAR D Avoid operating the A T V through deep or fast-flowin g water . If it's unavoidabl[...]

31 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating this A T V with improper tires, or with improper or uneven tire pressure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improp er or uneven tire pressure, could cause loss of control or accident. HOW TO A VOID THE HAZAR D Always use the size and type of tires s[...]

32 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Overloading the A TV or carrying/ towing carg o improperly . WHA T CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could le ad to loss of control or a n accident. HOW TO A VOID THE HAZAR D Never exceed the stated load capacity for this A TV . Cargo shou ld be prop[...]

33 SAFETY Operator Safety WA R NI N G Operating a da maged A T V can result in an accident with serious injury o r death. Afte r any overturn or accid ent, have a qualified service dealer inspect the entire ma chine for possible dama ge, including (but not limited to) brakes, throttle and st eering systems. WA R NI N G Safe operation of this rider [...]

34 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 power while backing, depress the override switch. NOTE: The override sw itch also allows activati on of All Wheel Drive in reverse, if the AWD switch is on. This switch is also used to toggle through th[...]

35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch to the center (OFF) position to stop the engine quickly . The st op switch provides the operator with a quick means of engine shutdown in case of stuck throttle or other emergency . The engine will not start or run when the switch is of f. NOTE: The taillight is on when ever[...]

36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are contro lled by pressing the throttle lever . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This A TV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck th[...]

37 FEA TURES AND CONTROLS Brake Systems The braking system is controlled by the two brake levers located on the handlebars. Service Brake Lever The service brake lever is located on the left handlebar . This lever controls both front and rear wheel braking action. Use this lever for normal braking. Apply the service brakes by squeezing the left bra[...]

38 FEA TURES AND CONTROLS Brake Systems Master Cylinders/Brake Fluid The master cylinders are located on the left and right handlebars. Check fluid levels before each use of the A TV . The fluid level can be seen through an indi cator window on the top of the master cylin- der . This eye will appear da rk when the fluid level is full. When fluid is[...]

39 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Squeeze and release the brake lever two or three times, then squeeze and hold. 2. Push the parking brake lock forward to engage the lock. 3. Release the brake lever . 4. T o rele ase the parking brake lock, squeeze and release the brake lever . It will return to its unlo[...]

40 FEA TURES AND CONTROLS Fu e l T a n k C a p Remove the fuel tank cap to a dd fuel to the fuel tank. Us e eith er leaded o r unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. F uel V alve The fuel valve is located on the left side panel. It has three positions: OFF: For vehicle storage and when trans[...]

41 FEA TURES AND CONTROLS 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 To change gears, stop the vehi- cle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while th e[...]

42 FEA TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter . The recoil starter is located on the right side of the vehicle. Follow the starting procedures on page 53, crank- ing the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly . 2[...]

43 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The Al l Wheel Drive sy stem is controlled by the A WD switch. When the switch is of f, the vehi- cle is in rear wheel drive at all times. When the switch is on, the vehicle is in A WD an d the front wheels will automatic ally engage any time the rear wheels lose trac- tion. When the rear whee[...]

44 FEA TURES AND CONTROLS All Wheel Drive (A WD) System Disengaging Wheel Hubs The hubs no rmally disengage when operating in reverse. However , one or both hubs may occasionally rema in engaged. If the handlebars pull to one side, one front hub is engaged. If both hubs are engaged, steering effort increases but remains balanced from left to right,[...]

45 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. Th e ins trument cluster me asures dis- tance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter functi on that limits the A TV's speed to approximately[...]

46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2. 5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over -volta ge may have occurr ed and the instrume nt cl uster may have shut off to protec[...]

47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Mode s The rider information center has 4 st anda rd modes. The reverse override button on the left handleba r is also the mode button. NOTE: If using the mo de button to program the rider information center , or to toggle through the option s, the transmission cannot be[...]

48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only . Plea se return your A TV to your dealer for all major repairs. As long as the gauge is in the diag nosti c mode, the wrench icon will remain lit. T o leave the diagnost ic mode, turn the key switch of f and [...]

49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Scr een 5: Programmable service interval The purpose of the pro grammable serv ice interval is to provide the con- sumer and dealer with a conven ient reminder fo r routine maintenance. When your vehicle leaves the factory , this fe ature is set at 50 hours. Y ou [...]

50 OPERA TION F uel Safety WA R NI N G Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme cautio n whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventil ated area. • Do not smoke or allow open flames or sparks in or near the area whe re refueling is pe[...]

51 OPERA TION Break-In P eriod The break-in period for your new Polaris A TV is the first ten ho urs of operation, or the time it takes to use the first two full ta nks of gasolin e. No single action on your part is as important as foll owing the proce- dures for a proper break-in. Careful treatment of a new engine and drive components will result [...]

52 OPERA TION Pre-Ride Checklist WA R NI N G If a proper inspection is not done befor e ea ch use, severe injury or death could result. Always in spect the vehicl e before each use to ensure it's in proper operating co ndition. Item Remarks P age Brake system/lever travel Ensure proper operation 37 85 Brake fluid Ensure proper level 38 Auxilia[...]

53 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking bra ke. NOTE: The starte r interlock will prevent the en gine from starting if the trans- mission is in gear and th e brake is not engaged. 4. T urn the fuel valve on. 5. Sit on the vehicle. NOTE: Do not use the ch[...]

54 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage the star ter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. 9. If the engine do es not start, return the key to the OFF position and wait five seconds before attemptin g to start again. Activate the starter fo[...]

55 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load distri bution warning labels on th e vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety decals. WA R NI N G Overloading the vehi cle[...]

56 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the car go. Do not attempt to dump or unload the vehicle while park ed on an incline. 2. Lock the parking bra ke. 3. Dismount the vehi cle. 4. Check car go distribution. If car go has shifted to the rear of the box, exercise caution. 5. Pull the car go box release lever forwar[...]

57 OPERA TION Hauling Cargo Load Distribution 1. Never exceed the maximum capac ities for hauling car go as stated on the load distrib ution warning labels and o n page 55. 2. Always load the cargo box with th e load as far forward as possible. 3. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling an[...]

58 OPERA TION Driving Safely Driving Procedures 1. W ear protec tive riding gear . See page 10. 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. See page 53. 4. Shift the transmission into gear . 5. Check you r surroundings and determine your path o f travel. 6. Release[...]

59 OPERA TION Driving Safely T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives all rear wheels equally at al l times. This means that the wheel on the outside of the turn must travel a greater d istance tha n the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direct[...]

60 OPERA TION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather , follow these precautions: 1. Slow down wh en enter- ing slippery areas. 2. Engage A WD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and av[...]

61 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (15 ° maximum). 3. Keep both feet on the footrests . 4. Shift your weight uphill. 5. Proc eed at a steady rate of speed and t hrottle opening. 6. Remain alert and be pre pared to take emer gency action. T[...]

62 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can dangerous and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill. 3. Keep your feet on the footrests. 4. S teer slightly into the hill to maintain veh[...]

63 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Apply the brakes slightly to gradually slow the vehicle. NOTE: Before operatin g your A TV , lear n how to use the auxil iary brake for emergency situations (if service brakes becom[...]

64 OPERA TION Driving Safely 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 park ing brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine . 3. Dismount on the uphill side of the ve hi [...]

65 OPERA TION Driving Safely Driving Through W a ter Y our A TV can operate throu gh water with a maximum recom- mended dep th equal to the bot- tom of the footrests. Follow these procedures when operat- ing throug h water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks hav e gradual inclines. 3. Procee[...]

66 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for ha zards such as logs, rocks and low hanging branches. WA R NI N G Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacle s are immediately visi[...]

67 OPERA TION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the veh icle. 2. Always avoid bac king downhill . 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sh arp angles. 6. Never open the throttle suddenly . 7. Never activate th[...]

68 OPERA TION Driving Safely P arking 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 gear . 3. Lock the parking bra ke. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off.[...]

69 EMIS SION 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 requi rements (40 CFR 205.158) and lo cal noi se level requirements. Operation on Public Lands in the U.S.A . Y our Polaris vehicle has a spa rk arrestor that was tested[...]

70 MAINTENANCE P eriodic Maintena nce 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 th[...]

71 MAINTENANCE P eriodic Maintena nce Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions .) Q Have an authorized Polaris dealer perform these services. Perform all ser[...]

72 MAINTENANCE P eriodic Maintena nce Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Q Brake pad wear 10 H Monthly 60 (100) Inspect periodica[...]

73 MAINTENANCE P eriodic Maintena nce Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Engine oil and filter change 100 H 6 M 620 (1000) Perfor[...]

74 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 70. Items not listed in the chart should be lubr icated at the general lubrication interval. NOTE: The a-arms and lower co ntrol arms are lubricated at the factory , and no additional lub ricat[...]

75 MAINTENANCE Lubrication Recommendations F ront Prop S haft Y oke AWD Hubs Ball Joint Middle Axle Bearings Center Swing Arm Housing Swing Arm Bushings Rear Axle Bearing Rear Stru t Tie Rod Ends 4:00 Pos i ti o n[...]

76 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 -5 0 oil. Follow the manufacturer's re commendatio ns for ambient tempera- ture operatio[...]

77 MAINTENANCE Engine Oil Oil Level The oil dipstick is on the left side of the A TV . 1. Position the vehicle on a level surface. 2. S tart the engine. Allow it to idle for 20-30 seconds. S top the engine. 3. Remove the dipstick. W ipe it dry with a clean cloth. 4. Reinstall the dipstick securely . NOTE: The dips tick must be fully installed to en[...]

78 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 70. 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 idle for two to three minutes. Sto p the engine. 3. Clean the area[...]

79 MAINTENANCE Oil and Filter Change 8. Reinstall the screen fitting and ro tate the fitting clockwise a mini- mum of 2 1/2 turns into the tank thr eads. Continue to rotate the fit- ting until the nipple of the fitting aligns with the mark on the tank. NOTE: Do not ove r -tighten. Maximum torque for the scree n fitting is 25 ft. lbs. (34 Nm). 9. Re[...]

80 MAINTENANCE 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's pressure[...]

81 MAINTENANCE T ransmission Oil Always check and ch ange the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. W e recommend the use of Polaris Premium AGL Synthe tic Gearcase Lubricant. See page 126 for the part numbers of Polaris[...]

82 MAINTENANCE F ront Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart beginning on page 70. Maintain the oi l level at the bottom of the fill hole threads. W e reco mmend the use of Polaris Premium A TV Angle Drive Fluid. See page 126 for the part numbers of Polaris products.[...]

83 MAINTENANCE Cooling System The engin e coolant level is controlled, or main tained, 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 the[...]

84 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[...]

85 MAINTENANCE Brakes Rear Brake The transmission brake is a hydrau- lic disc brake. This brake is acti- vated by the left brake lever , which also activates the front brakes. The transmission brake system is self- adjusting. Periodically check the brake pads for wear . Replace brake pads when they are worn to 3/64" (1 mm). Periodically inspec[...]

86 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) to e out. 1. Position the vehicle on a level surface. 2. Place the hand lebars in a straight-ahead positi on. 3. T ie a length of string between two stands as shown in the illustratio[...]

87 MAINTENANCE Steering Assembly The steering assemb ly of the A TV should be che cked periodically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the veh icle. Side P anel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. W ith a quick and firm mo[...]

88 MAINTENANCE Tires Refer to the specifications section beginning on page 124 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking bra ke. 4. Loosen the wheel nuts slight[...]

89 MAINTENANCE Tires Wheel Installation 1. Place the transmission in gear . 2. Lock the parking bra ke. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and fin- ger -tighten them. Make sure the tapered side of the rear wheel nut fits int[...]

90 MAINTENANCE Air Filter Always inspect and replace the air fi lter at the intervals outlined in the Periodic Maintenance Char t beginni ng on page 70. 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-fil- ter from the main filter . W as[...]

91 MAINTENANCE Breather Filter/Hose Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Ch art beginn ing on page 70. 1. Remove the hose clamps from the filter and pull the filter out of the hoses. NOTE: It's not necessary to remove the lower hose from the engine. 2. Inspect the filter for debri[...]

92 MAINTENANCE Lights When servicing a ha logen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Remove the screw from the rear of the pod. 3. Lift[...]

93 MAINTENANCE Lights 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 wal l. Lock the parkin g brake. 2. Measure the distance from the floo r to the center of t[...]

94 MAINTENANCE Lights 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 sm[...]

95 MAINTENANCE Lights T aillight/Brakelight Lamp Replace ment 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly . 2. Remove the lamp. 3. Apply dielectric grease to the socket and install the new lamp. 4. T est the light for proper ope ra- tion. 5. Reinstall the gasket and lens cover . [...]

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifi cations section beginning on p age 124 for the recom- mended spark pl ug type and gap for your vehicle. Always to rque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition afte[...]

97 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spar k Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be fl aky and white. A white insulator ti[...]

98 MAINTENANCE V ehicle Immersion 1. If it's impossible to take yo ur A TV to a dealer before starting it, fol- low the steps outlined below . 2. Move the A TV to dry land or at the very least, to water below the footrests. 3. Check the air bo x. If water is present, dry th e air box and replace the filter with a new filter . 4. T urn the fuel[...]

99 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur g e accumulated carbon from the exha ust pipe /muf fler . 1. Remove the arrestor c lean- out plug from the bottom of the muf fler . 2. Place the transmission in neutral. 3. S tart the engine. 4. Quickly squeeze and release the throttle lever several times to pur ge carbo[...]

100 MAINTENANCE PVT System WA R NI N G F ailure to comply with th e instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed. The PVT system has been precision ba lanced. Any modification will cause the system to be[...]

101 MAINTENANCE PVT 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[...]

102 MAINTENANCE PVT System When T o Use Low Range and High Range PVT 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. Remove the drain plug. Allow the water to drain completely . Rein- stall the drain plug. 2. S tart the engine. Place the [...]

103 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A seale d battery can be identified by its flat covers on the top of t he battery . A conventional battery has six filler caps on the top of the battery . Conventional Battery Always keep battery terminals and conne[...]

104 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[...]

105 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged 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 107 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in t[...]

106 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recharge as needed to mainta in a full char ge. NOTE: Power p[...]

107 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery char ging instructions apply only to the installa- tion of a sealed battery . Read all instru ctions befo re proceeding with the installation of this battery . The sealed battery is alrea dy filled w ith electrolyte and has been sealed and fully char ged a t the factory[...]

108 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 h ours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top of bat tery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None require[...]

109 MAINTENANCE Cleaning and Storage 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 components. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleaning[...]

110 MAINTENANCE Cleaning and Storage 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: • Wheel bearin gs • Radiator • T ransmission sea ls •[...]

111 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recomme nded. See page 109. F og the Engine 1. Support the front end of the machine so t he engine is level or tilted slightly rearward. 2. Remove the spark plug. Rotate th e piston to BDC and p our two ounces (59 ml) o f engine[...]

112 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as recommen ded in the Periodic Maintenance Chart beg inning on page 70. • Front demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the flui d looks dark or [...]

113 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 70. Engine Anti-F reeze T est engine coola nt strength and ch ange if necessary . Replace coolant every two years. Battery Storage See pages 106-107 f[...]

114 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking bra ke. 4. Secure the fuel cap, oil ca p and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or ro pe. Do not attach tie strap[...]

115 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four hand lebar bolts. 3. Adjust the handlebar to t he desired heigh t. NOTE: Be sure the handlebars do not contact the gas tank or any other pa rt of the machin[...]

116 ADJUSTMENTS Throttle Cable F reeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

117 ADJUSTMENTS F ront Drive Chain Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain. Then p ull up and down on the chain. At this point the chain should have 3/16"-3/8" (5-9 mm) deflection. If the chain needs adjust- ment, use the following proce dure. 1. Remove the ch[...]

118 ADJUSTMENTS Rear Axle Drive Chain T o a djust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. T o tal slack for the rear ch ain should be adjusted to 3/6"-3/8" (6-9 mm) at the tightest point in the chain. Optional Susp ension Springs Al[...]

119 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrate d at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) o r higher . Ab ove 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea [...]

120 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 64). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequen[...]

121 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solution Out of fuel T urn fu[...]

122 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommended fue l Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plug(s)[...]

123 TROUBLESHOOTING Engine Stops or Loses P ower Engine Overheating Possible Cause Solution Out of fuel R efuel, 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 wi th new fuel Foule[...]

124 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 6X6 Maximum W eight Capacity 1090 lbs. ( 494 kg) (includes operator , cargo, accessories) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. ( 1.9 l) Coolant Capacity 2.25 qts. (2 l) T ransmission Oil Capa city 32 oz. (948 ml) Front Gearcase Oil Capacity 4 oz. (120 ml) Front[...]

125 SPECIFICA TIONS Clutching Ch art Jetting Chart Sportsman 500 6X6 T ransmission Automatic PVT (H/L/N/R) Gear Reduction, Low 6 .69:1 Gear Reduction, Reverse 5 .17:1 Gear Reduction, Forward 3.34:1 Drive Ratio, Fron t 2:1 Drive Ratio, Final 12:38 80P T ires/Pressure, Front Polaris PXT 25x8-12 / 5 psi T ires/Pressure, Ce nter Pola ris PXT 25x1 1-10 [...]

126 POL ARIS PRODUCTS Pa rt Number Description Engine L ubricant 2870791 F og ging Oil (12 oz. Aerosol) 2876244 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL S[...]

127 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris Light Utilit y V ehicle 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 covers [...]

128 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris l imited warranty exclude s any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any veh[...]

129 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED T O THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND 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 ARRAN TY . Some states do not allow limi- tations on ho[...]

130 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEA LER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deal[...]

131 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in wh ich the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you ha[...]

132 W ARRANTY California Emission Control W arranty Statement Y our W arranty Rights and Obli gations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2006 and later Large Spark Ignition Engine ([...]

133 W ARRANTY California Emission Control W arranty Statement Limited W arranty California Only POLARIS warrants to the owner of 2006 and la ter LSI engines that the LSI engine (1) has been designed, built, and eq uipped at the time of manufactu re so as to conform with the applicable regulations of the Ca lifornia Air Resources Board and, (2) is f[...]

134 W ARRANTY California Emission Control W arranty Statement What is Not Covered Un der This Wa rranty This warranty does not cover a ny emission-related part, which malfunctions, fails, or is damaged due to alterations an d/or modifications such as changing, adding, or removing parts. When the LSI engine is being serviced un der warranty , POLARI[...]

135 W ARRANTY California Emission Control W arranty Statement Repair and Replac ement of Emission-Related P arts It is recommended that only LS I engine replacemen t p arts, which have been authorized and approved by POLARIS, shoul d be u sed in the performan ce of any warranty mainte- nance or repairs of emission-re lated parts. These replacemen t[...]

136 W ARRANTY U.S.A . EP A Emissions Limited Wa rranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions lim ited warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the[...]

137 MAINTENANCE L OG 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 (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS[...]

138 MAINTENANCE L OG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

139 MAINTENANCE L OG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS[...]

140 INDEX A Age Restrictions . . . . . . . . . . . . . . . . 12 Air Box Drain . . . . . . . . . . . . . . . . . 90 Air Filt er . . . . . . . . . . . . . . . . . . . . . 90 All Wheel Drive Syst em . . . . . . . . . 43 AWD Switch . . . . . . . . . . . . . . . . . . 43 AWD System . . . . . . . . . . . . . . . . . . 43 B Battery . . . . . . . . . . . .[...]

141 INDEX I Idle RPM Adju stment . . . . . . . . . . . 119 Immersion . . . . . . . . . . . . . . . . . . . . . 98 Instrument Clus ter . . . . . . . . . . . . 45-49 J Jetting Chart . . . . . . . . . . . . . . . . . . 125 K Key Switch . . . . . . . . . . . . . . . . . . . . 35 K-Turn . . . . . . . . . . . . . . . . . . . . . . . 64 L Lights . . . . .[...]

142 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . 95 Throttle Body Adjustment . . . . . . . 116 Throttle Cable Freeplay . . . . . . . . 116 Throttle Lever . . . . . . . . . . . . . . . . . 36 Tire Tread Depth . . . . . . . . . . . . . . . 88 Tires . . . . . . . . . . . . . . . . . . . . . . 88-89 Front Wheel Hub Tightening . . 88 Wh[...]