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Polaris Sportsman 9921309 Owner's Manual

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  • Page 2 When parking on grades, leave shift in forward. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. Pantone 626 cvc For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com...
  • Page 3 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 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 6: Table Of Contents

    Specifications ......124 Polaris Products..... . . 126 Warranty .

  • Page 8: Know Your Vehicle

    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

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 10: Tire Pressure/Load Warning

    SAFETY Safety Decals and Locations Reverse Override Warning Front Rack Warning Tire Pressure/Load Warning Tire Pressure/Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) CENTER 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 1090 LBS.

  • Page 11: Age 16 Warning

    Safety Decals and Locations Age 16 Warning Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. Container/No Passenger Warning WARNING Remove flammable containers from box before refueling.

  • Page 12: All Wheel Drive Switch

    SAFETY Safety Decals and Locations All Wheel Drive Switch Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS.

  • Page 13: Safe Riding Gear

    Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 14: 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 15: Operator Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A...

  • Page 16: Safety Training

    Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly...
  • Page 17 Operator Safety 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, on your vehicle or in this manual, alerts you to the potential for injury.
  • Page 18 • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse •...
  • Page 19 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. • Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. • Never operate on hills too steep for the ATV or for your abilities.
  • Page 20 • Always remove the ignition key when the vehicle is not in use to pre- vent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342- 3764.

  • Page 21: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 22 ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING contact ATV Enrollment WARNING SAFETY...
  • Page 23 Operator Safety POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. A passenger riding on a rack or in the cargo bed can fall from the vehicle, which could result in serious injury.
  • Page 24 Operator Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 25 Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 26 Operator Safety POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving. POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.
  • Page 27 Operator Safety POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could contact the rear wheels and lead to accident...
  • Page 28 Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you've...
  • Page 29 SAFETY Operator Safety POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees.
  • Page 30 Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill.
  • Page 31 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 32 Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 33 SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 34 HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
  • Page 35 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/ towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 36 Operator Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 37: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.

  • Page 38: Engine Stop Switch

    Switches Engine Stop Switch Move the stop switch to the center (OFF) position to stop the engine quickly. The stop 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 off.

  • Page 39: Throttle Lever

    The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the...

  • Page 40: Brake Systems

    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.
  • Page 41 If the fluid level is low add DOT 4 brake fluid only. Do not overfill. See page 126 for the part numbers of Polaris products. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.

  • Page 42: Parking Brake

    Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Squeeze and release the brake lever two or three times, then squeeze and hold.

  • Page 43: Fuel Tank Cap

    FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel Fuel Tank to the fuel tank. Use either leaded or Fuel Valve unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Valve The fuel valve is located on the left side panel.

  • Page 44: Transmission Gear Selector

    Transmission 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.

  • Page 45: Recoil Starter

    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.
  • Page 46 All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is off, the vehi- cle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the front wheels will automatically engage any time the rear wheels lose trac- tion.

  • Page 47: Tool Kit

    All Wheel Drive (AWD) System Disengaging Wheel Hubs The hubs normally disengage when operating in reverse. However, one or both hubs may occasionally remain 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, and vehicle speed is somewhat restricted.

  • Page 48: Instrument Cluster

    Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures dis- tance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph.

  • Page 49: Rider Information Center

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As...
  • Page 50 Instrument Cluster Rider Information Center Standard Modes The rider information center has 4 standard modes. The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the transmission cannot be in reverse.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.

  • Page 52: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the con- sumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable the programmable service interval before it can be used.

  • Page 53: Operation

    OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 54: Break-In Period

    Break-In Period The break-in period for your new Polaris ATV 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 is as important as following the proce- dures for a proper break-in.

  • Page 55: Pre-Ride Checklist

    Ensure proper operation Ensure operation Ensure proper operation 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 Check condition and operation of the...

  • Page 56: Starting The Engine

    Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3.
  • Page 57 OPERATION Starting the Engine 8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 9. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again.

  • Page 58: Hauling Cargo

    Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety decals. Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability.
  • Page 59 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution.

  • Page 60: Load Distribution

    Hauling Cargo Load Distribution 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 55. 2. Always load the cargo box with the load as far forward as possible. 3. Always operate the vehicle with extreme caution whenever hauling or towing loads.

  • Page 61: Driving Safely

    OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. See page 53. 4.

  • Page 62: Turning The Vehicle

    Driving Safely Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives all rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 63: Driving On Slippery Surfaces

    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 when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction.

  • Page 64: Driving Uphill

    Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 65 Driving Safely Driving on a Sidehill (Sidehilling) Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.

  • Page 66: Driving Downhill

    Driving Safely Driving Downhill Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down. Hard use of the braking system while descending a hill could result in a front- end overturn, causing serious injury or death. Always operate the brakes slightly when descending a hill.
  • Page 67 Driving Safely 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. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 68: Driving Through Water

    Driving Safely Driving Through Water Your ATV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these procedures when operat- ing through water: 1. Determine water depths and current before crossing. 2.

  • Page 69: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 70: Driving In Reverse

    Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.
  • Page 71 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.

  • Page 72: Emission Control Systems

    CFR 205.158) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 73: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 137.

  • Page 74: Maintenance Chart Key

    E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
  • Page 75 (if equipped) Drive belt Cooling system (if applicable) 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 Miles (Km)
  • Page 76 Idle speed Toe adjustment Auxiliary brake 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) Miles (Km) 100 H 620 (1000) Perform a break-in oil change...

  • Page 77: Lubrication Recommendations

    O-ring chain lube or SAE 80/ Gear Selector Oil PS-4 PLUS Performance Synthetic 2W-50 Transmission Oil Polaris Premium Synthetic Gearcase Lube Front Prop Shaft Yoke Polaris Premium U-Joint Lube AWD Hubs Premium Demand Drive Hub Fluid Ball Joint Polaris Premium all Season Grease or grease conform- ing to NLGI No.
  • Page 78 MAINTENANCE Lubrication Recommendations Front Prop Shaft Yoke Tie Rod Ends Swing Arm Bushings AWD Hubs Middle Axle Bearings Ball Joint 4:00 Position Center Swing Arm Housing Rear Strut Rear Axle Bearing...

  • Page 79: Engine Oil

    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 80: Oil Level

    Engine Oil Oil Level The oil dipstick is on the left side of the ATV. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick. Wipe it dry with a clean cloth.

  • Page 81: Oil And Filter Change

    MAINTENANCE Oil and Filter Change Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil.
  • Page 82 Oil and Filter Change 8. Reinstall the screen fitting and rotate the fitting clockwise a mini- mum of 2 1/2 turns into the tank threads. Continue to rotate the fit- ting until the nipple of the fitting aligns with the mark on the tank. NOTE: Do not over-tighten.

  • Page 83: Oil Pump Priming

    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 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 relief slit.

  • Page 84: Transmission Oil

    Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 126 for the part numbers of Polaris products.

  • Page 85: Front Gearcase Oil

    Periodic Mainte- nance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Polaris Premium ATV Angle Drive Fluid. See page 126 for the part numbers of Polaris products.

  • Page 86: 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 already premixed and ready to use. Do not dilute with water. See page 126 for the part numbers of Polaris products.

  • Page 87: Radiator Coolant

    Radiator Coolant To ensure that the coolant maintains 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 cooling system has been drained for maintenance or repair.

  • Page 88: Rear Brake

    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.

  • Page 89: Toe Alignment

    1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING Stand String...

  • Page 90: Side Panel Removal

    Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.

  • Page 91: Wheel Removal

    6. Remove the wheel nuts. 7. Remove the wheel. 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. WARNING 1/8" (3 mm)

  • Page 92: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in gear. 2. Lock the parking brake.

  • Page 93: Air Filter

    MAINTENANCE Air Filter Always inspect and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3.
  • Page 94 Breather Filter/Hose Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Chart beginning 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.

  • Page 95: Headlight Lamp Replacement

    MAINTENANCE Lights When servicing a halogen 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. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 96: High Beam Adjustment

    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 surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Lock the parking brake. 2.

  • Page 97: Headlight Housing Replacement

    MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower 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 disconnect the speedometer harnesses from the speedometer.
  • Page 98 Lights Taillight/Brakelight Lamp Replacement 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. Test the light for proper opera- tion.

  • Page 99: Spark Plugs

    Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 124 for the recom- mended spark plug type and gap for your vehicle. Always torque spark plugs to specification.

  • Page 100: Recoil Housing

    Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan 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 flaky and white.

  • Page 101: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. 1. If it's impossible to take your ATV to a dealer before starting it, fol- low the steps outlined below.

  • Page 102: Spark Arrestor

    Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

  • Page 103: 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 104 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 105: Pvt Drying

    PVT System When To Use Low Range and High Range Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) PVT Drying There may be some instances when water is accidently ingested into the PVT system.

  • Page 106: Conventional Battery

    Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

  • 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 Installation

    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 can also hinder vehicle performance. Follow the battery charging instructions on page 107 before installing the battery.

  • Page 109: Battery Storage

    Power plug leads may need to be bent down so that the battery cover can be installed. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 110 Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installa- tion of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 111 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action charger @ standard amps specified on top of battery)

  • Page 112: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 113: Polishing The Vehicle

    • Cab and body panels • Labels and decals NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

  • Page 114: Storage Tips

    6. Treat the fuel system with Polaris Carbon Clean. See page 112. 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 115 • Coolant (test strength/fill) 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. NOTE: Carbon clean will also reduce the possibility of bacterial growth in the fuel system.
  • Page 116 Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. Please see your Polaris dealer. MAINTENANCE...

  • Page 117: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.

  • Page 118: Adjustments

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.

  • Page 119: Throttle Cable Freeplay

    ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.
  • Page 120 Front Drive Chain Operating the vehicle with the drive chain slack out of specification could cause serious damage to the transmission and drive components. Never operate the vehicle with the drive chain slack out of specification. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain.
  • Page 121 NOTE: Optional springs may be a different color than standard springs. Springs may be painted to a desired color using Polaris touch-up paint, available through Polaris dealers. SOFT Front Strut Spring 3/16"-3/8"...
  • Page 122 Carburetor Your Polaris ATV is calibrated 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.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in...

  • Page 123: Troubleshooting

    Dry out the PVT. See page 102. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
  • Page 124 Replace with fresh recommended fuel Turn the fuel valve on Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Recharge the battery to 12.8 VDC See your dealer...
  • Page 125 Add or change fuel, clean the fuel system Inspect and replace Replace with recommended fuel Replace filter Replace with recommended fuel See your Polaris dealer Solution Replace with lower octane fuel Inspect, clean and/or replace spark plugs Allow engine to warm up before operat-...
  • Page 126 Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in 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 Incorrect fuel...

  • Page 127: Specifications

    142.5 Q-4M (829) 4HB41-3 DC CDI 30 +/- 2 BTDC @ 5000 RPM NGK BKR5E / 0.036" (.9 mm) Dry Sump Automatic PVT (Polaris Variable Transmission) MacPherson strut with 6.7" (17 cm) travel Progressive rate with 7.5" (19 cm) travel...

  • Page 128: Clutching Chart

    (6000-12000) Sportsman 500 6X6 Automatic PVT (H/L/N/R) 6.69:1 5.17:1 3.34:1 12:38 80P Polaris PXT 25x8-12 / 5 psi Polaris PXT 25x11-10 / 5 psi Polaris PXT 25x11-10 / 5 psi Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic lock, all wheel...

  • Page 129: Polaris Products

    Chain Lube, Aerosol (16 oz.) 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 130: Warranty

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
  • Page 131 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 132 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer.
  • Page 133 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 134 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 135 Manufacturer's Warranty Coverage: The 2006 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner's Warranty Responsibilities: • As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's...

  • Page 136: Limited Warranty

    Limited Warranty California Only POLARIS warrants to the owner of 2006 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and, (2) is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below.

  • Page 137: Maintenance Schedule

    When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
  • Page 138 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emis- sion-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-888-704-5290 and you will be advised of the appro- priate dealer where the warranty repair is to be performed.
  • Page 139 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 140: 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 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 141 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 142 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 143: Index

    Age Restrictions....12 Air Box Drain ....90 Air Filter ..... 90 All Wheel Drive System .
  • Page 144 Parking on an Incline ... . 68 Periodic Maintenance Chart ..70-73 Polaris Product List... . . 126 Polishing the Vehicle ... 110 Pre-Ride Checklist .
  • Page 145 Taillight ..... . 95 Throttle Body Adjustment ..116 Throttle Cable Freeplay ..116 Throttle Lever .

This manual is also suitable for:

2008 sportsman 500 6x6

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