Polaris Sportsman 9921837 Owner's Manual
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Polaris Sportsman 9921837 Owner's Manual

Polaris Sportsman 9921837 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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  • Page 3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles/Tractors • RANGER utility vehicles •...
  • Page 4 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 5: Table Of Contents

    Specifications ......116 Polaris Products..... . . 118 Troubleshooting .

  • Page 6: Introduction

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 7: Safety

    Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Tractor is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    Record your vehicle's identification 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 your key number) and mating it with one of your existing keys.

  • Page 9: Safety

    You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis. If you purchased a used Polaris Tractor from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

  • Page 10: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 11: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 12 Never operate a Tractor without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Tractor dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the Tractor unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 13 SAFETY Rider Safety Never carry a passenger on this vehicle. Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating a Tractor. Never operate at excessive speeds.
  • Page 14 Never turn sharply at excessive speeds, which can lead to vehicle overturn. If a Tractor has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
  • Page 15 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 46. Never operate on hills too steep for the Tractor or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.
  • Page 16 SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 50. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 17 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving in reverse. See page 56. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Tractor through improper installation or use of accessories.
  • Page 18 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about Tractor safety, contact an authorized Polaris Tractor dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 19: General Alert

    Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

  • Page 20: Tire Pressure/Load Alert

    SAFETY Safety Labels and Locations Reverse Override Rack Warning Tire Pressure/Load Alert TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information. Reverse Override Alert/4X4 (AWD) Switch WARNING Pushing reverse override button may cause sudden increases in power and...

  • Page 21: No Passenger" Warning

    SAFETY Safety Labels and Locations “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Clutch Cover Alert NO STEP 7173030 Rack Warning WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.

  • Page 22: Features And Controls

    FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Master Light Engine Stop Switch Switch Hazard Switch Headlight 4X4 Switch Switch Horn Switch Main Key Switch Turn Signal Switch Master Light Switch The master light switch must be in the ON position to allow operation of the headlights, parking lights and taillights.

  • Page 23: Main Key Switch

    Switches Main Key Switch End all electrical power to the vehicle. The LIGHTS ON position turns the headlights on. The master light switch must be on and the engine stop switch must be in the RUN position. Start the engine. The headlights are not on in this position.

  • Page 24: X4 Switch

    Switches 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 28. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

  • Page 25: Throttle Lever

    FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Tractor. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine.

  • Page 26: Parking Brake

    Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

  • Page 27: Backrest Adjustment

    FEATURES AND CONTROLS Seat Load Adjuster Seat Load Adjustment Adjust the seat spring for the comfort of a lighter or heavier operator. Reach under the rear rack to access the adjuster. Tighten the spring for heavier riders. Loosen the spring for lighter rid- ers.

  • Page 28: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine. 1. Turn the handlebars to the full right position.

  • Page 29: Fuel Tank Cap

    Hitches Hitch Installation/Removal 1. Release the wire lock from the 12.7 mm pin and remove the pin. 2. Install the hitch to the receiver. 3. Install the 12.7 mm pin through the bore of both the receiver and the hitch. Secure the wire lock. Make sure the hitch assembly is secure at that the wire lock is properly engaged over the pin.
  • Page 30 FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

  • Page 31: Engaging 4X

    All Wheel Drive (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

  • Page 32: Engaging Active Descent Control

    FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:...

  • Page 33: Instrument Cluster

    Instrument Cluster The instrument cluster senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h.

  • Page 34: Rider Information Center

    If this occurs, take the vehicle to your Polaris dealer for proper diag- nosis. 1. Gear Indicator - This...
  • Page 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or kilometers traveled by the Tractor.
  • Page 36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4).
  • Page 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle 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 Center, depending on your preference.
  • Page 39 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 39 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.
  • Page 41 Instrument Cluster Rider Information Center Downloading Codes Blink Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage...

  • Page 42: Operation

    Break-In Period The break-in period for your new Polaris Tractor is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your Tractor more than following the procedures for a proper break-in.

  • Page 43: Pre-Ride Checklist

    Ensure proper operation Adjust for best side/rear vision Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 44: Starting The Engine

    Starting the Engine NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK (or neutral). 3.

  • Page 45: Cold Weather Operation

    Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

  • Page 46: Driving Procedures

    Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 41. 3. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 4. Start the engine and allow it to warm up. 5.

  • Page 47: Turning The Vehicle

    Turning the Vehicle 1. Before turning, activate a turn signal to alert oth- ers of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while sup-...

  • Page 48: Driving Uphill

    OPERATION Driving Uphill 25° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4.
  • Page 49 OPERATION Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3.
  • Page 50 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4.

  • Page 51: Driving Downhill

    OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4.
  • Page 52 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 53 Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. 11. Apply the foot brake. 12. With the transmission still in forward, start the engine. 13. Squeeze and release the brake lever to release the parking brake. 14.

  • Page 54: Driving Through Water

    OPERATION Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.
  • Page 55 OPERATION Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 98. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water.

  • Page 56: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid skid Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1.

  • Page 57: Driving Over Obstacles

    Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. Parking on an Incline Avoid parking on an incline.

  • Page 58: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5.

  • Page 59: Hauling Cargo

    Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels.

  • Page 60: Towing Loads

    Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Tractor/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°.
  • Page 61 Never install a hitch longer than 10 cm. Never install auto- motive accessories on your Polaris Tractor. Always install Polaris-approved (or equivalent) accessories designed for Tractor use.

  • Page 62: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 63: Maintenance

    MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 31. Record maintenance and service in the Maintenance Log beginning on page 126.

  • Page 64: Periodic Maintenance Chart

    Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission-related service Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item Steering Front suspension...
  • Page 65 Periodic Maintenance Chart Item Hours Calendar Kilometers Air filter, main element Brake pad wear Battery Demand drive fluid Rear gearcase oil (if equipped) Transmission oil Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Shift linkage Steering Front suspension Rear suspension Throttle cable/ ETC switch...
  • Page 66 Fuel filter Spark arrestor Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Kilometers 12 M 1600...

  • Page 67: Lubrication Guide

    Item Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Brake Fluid DOT 4 Only Transmission Oil Polaris AGL Synthetic Gearcase Lube Demand Drive Demand Drive LT Fluid (Front Premium Fluid Gearcase) ADC Fluid Polaris ADC Fluid...

  • Page 68: Specifications

    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 Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.

  • Page 69: Oil Level

    Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth.

  • Page 70: Engine Oil

    MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Clean the area around the drain plug.
  • Page 71 Engine Oil Oil and Filter Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads.
  • Page 72 Engine Oil Oil and Filter Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. TIP: If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 71.

  • Page 73: Oil Pump Priming

    Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

  • Page 74: Polaris Products

    Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 118 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Premium AGL Synthetic Gearcase Lubricant Transmission Oil Level 1.

  • Page 75: Transmission Oil Change

    Transmission Oil Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug.

  • Page 76: Fluid Level

    Use the recommended fluid. Fill Plug Use of other fluids may result in improper operation of components. See page 118 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole Fill Level threads. Drain Plug Fluid Level 1.
  • Page 77 Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6.
  • Page 78 Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 118 for the part numbers of Polaris products. Fluid Level 1.

  • Page 79: Fluid Change

    Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

  • Page 80: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 118 for the part num- bers of Polaris products.

  • Page 81: Radiator Coolant

    Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Open the access door. 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck.

  • Page 82: Brake Fluid

    Never operate the Tractor with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 118 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 83 Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.

  • Page 84: Foot Brake

    Brake Fluid Foot Brake The foot brake fluid reservoir is located under the seat. 1. Position the vehicle on a level surface. 2. Remove the seat. 3. View the fluid level in the reservoir. 4. Remove the cap and add the recommended fluid as needed.

  • Page 85: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 86: Toe Alignment

    3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. Stand...

  • Page 87: Handlebar Adjustment

    Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference.

  • Page 88: Side Panel Removal

    MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it.

  • Page 89: Throttle Cable Freeplay

    Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 90: Tire Tread Depth

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service.
  • Page 91 Tires Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5.

  • Page 92: Fuel Filter

    MAINTENANCE Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Air Filter Always clean and replace the air and breather filters at the intervals out- lined in the Periodic Maintenance Chart beginning on page 61.
  • Page 93 Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 86. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3.

  • Page 94: High Beam Adjustment

    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 95 Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 96 MAINTENANCE Lights Taillight/Brake Light Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counter- clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation.

  • Page 97: Fuse Replacement

    Fuse Replacement Fuse If the engine stops or will not start, or if you experience other electrical fail- ures, a fuse may need replacement. Spare fuses are provided in a compart- ment on the top of the access door. 1. Open the front box cover. 2.

  • Page 98: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 116 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.
  • Page 99 Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 86. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup.

  • Page 100: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro- cedure. NOTICE: If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.
  • Page 101 Vehicle Immersion 4. Turn the ignition key past the PARKING LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 7.

  • Page 102: Spark Arrestor

    Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined.
  • Page 103 Spark Arrestor 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeat- ing step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front.

  • Page 104: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 105: Pvt Drying

    PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.
  • Page 106 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention.

  • Page 107: Battery Removal

    Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 108: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Polaris recommends maintaining battery charge by using a Polaris Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge.
  • Page 109 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 105. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 110 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

  • Page 111: Cleaning And Storage

    Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 112: Polishing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 113 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 114: Storage Tips

    109. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 115 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
  • Page 116 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 117: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Tractor to the transporting unit securely with suitable straps or rope.

  • Page 118: Specifications

    350 w 10.2:1 Electronic Fuel Injection Electronic Ignition 10 +/- 1 BTDC @ idle NGK BKR6E .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Dry Sump Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel...
  • Page 119 Sportsman 500 EFI Tractor Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Parking Lights Taillights Brake Light Instrument Cluster Clutching (EBS Models) Altitude Meters 0-1800 (Feet) (0-6000)

  • Page 120: Polaris Products

    Premium U-Joint Lube (414 ml) 2871329 Dielectric Grease (Nyogel 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 121: Troubleshooting

    Dry out the PVT. See page 103. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Always warm up the belt by operating below 40 km/h for 1.5 km (8 km or more when temperature is below freez- ing).
  • Page 122 Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...
  • Page 123 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 124: Engine Overheating

    Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter...

  • Page 125: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE.
  • Page 126 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 127 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris Tractors. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 128: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 129 MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 130: Index

    INDEX 4X4 System ....28-29 Accessories ....114 Active Descent Control Fluid .
  • Page 131 Fluid Change ADC Fluid....77 Demand Drive....75 Engine Oil ....68-71 Front Gearcase .
  • Page 132 Parking on an Incline ... . 55 Periodic Maintenance Chart ..61-64 Polaris Product List ... . 118 Polishing the Vehicle... 110 Position Light Lamp .
  • Page 133 Tires ..... . 88-89 Wheel Installation ... 89 Wheel Nut Torque ..88 Wheel Removal.

This manual is also suitable for:

2009 sportsman 500 efi tractor

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