Sportsman Touring 500 HO Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800- 342-3764 for assistance.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923799 Rev 01 Printed in USA *9923799...
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
POLARIS and SPORTSMAN are registered trademarks of POLARIS Industries Inc. Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.
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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Failure to heed the warnings and safety precautions 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.
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.
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members.
Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Equipment Modifications 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.
SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
SAFETY Safety Warnings Handling Gasoline 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.
SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).
SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.
SAFETY Safety Warnings Physical Control of the ATV 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 a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.
SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 54. Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Lean forward to keep body weight uphill. A passenger should also lean uphill.
SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.
SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 59):...
SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water unless you have independently veri- fied that the ice is sufficiently thick to sup- port the weight and moving force of the...
SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. 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. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.
If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Passenger Warning/Discretionary Warning...
SAFETY Safety Labels and Locations General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: •...
SAFETY Safety Labels and Locations Rack Rack Warning Warning Hitch Capacity Clutch Cover Warning Tire Pressure/Load Warning Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. •...
SAFETY Safety Labels and Locations Rack Warning WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7172572 Clutch Cover Warning WARNING...
FEATURES AND CONTROLS Switches Engine Headlight Switch Stop Switch Switch Mode/Reverse Override Main Key Switch Switch Choke Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING! Activating the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.
FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.
FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.
FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4.
FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the vehicle. Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop.
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will be Switch...
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation.
If this occurs, take the ATV to your POLARIS dealer for proper diagnosis. 1. Gear Indicator - This...
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 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV.
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.
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. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
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.
Break-In Period The break-in period for your new POLARIS ATV is the first 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3.
OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.
Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.
OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 44. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.
OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2.
OPERATION Driving with a Passenger 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a pas- senger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 55. 13.
OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the out- side wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.
OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.
OPERATION Driving Uphill 15° Maximum Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (15° maximum). 3.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.
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. 8 ft. (2.4 m)
OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount.
OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Avoid steep hills (15° maximum). 2. Always check the terrain carefully before descending a hill. 3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before enter- ing water. 2. Choose a crossing where both banks have gradual Maximum Depth inclines.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.
OPERATION 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 PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never carry cargo on the rear rack when operating the ATV in the 2-up mode with a passenger.
OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accor- dance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.
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 135.
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. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Air filter, Weekly Inspect; replace as needed main element Recoil housing Weekly Drain water as needed, (if applicable) check often if operating in wet conditions Brake pad wear 10 H Monthly...
3000 (4800) Clean out D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Demand Drive 9 oz. (265 ml) See page 79. Fluid (Front PLUS Fluid Gearcase) Front Prop Shaft POLARIS Pre- Grease fittings (3 pumps Yoke mium U-Joint Lube maximum) every 500 miles, before long periods of stor- age, or after pressure wash- ing or submerging.
POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 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 recommenda- tions for ambient temperature operation.
MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube Dipstick from the left side of the ATV. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. 3.
MAINTENANCE Engine Oil Oil and Filter Change 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine.
MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2"...
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain the oil level at the bottom of the fill plug hole threads. POLARIS recom- mends the use of POLARIS AGL PLUS Transmission Fluid for this transmission.
MAINTENANCE Transmission Oil Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. Drain (27-34 Nm).
Periodic Maintenance Chart beginning on page 67. We rec- ommend the use of Demand Drive PLUS Fluid. Use of other fluids may result in improper operation of components. See page 126 for the part numbers of POLARIS products. Maintain the fluid level at Fill...
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4.
Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Premium 60/40 anti- freeze/coolant 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.
MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle. 1. Remove the left side panel. See page 86. 2. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
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.
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. 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.
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.
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 Removal 1. Stop the engine. 2. Place the transmission in PARK.
MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 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 finger-tighten them. 5.
MAINTENANCE Air Filter 1. Remove the seat. Pre-Filter 2. Release the air box cover clips, Main Filter and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre- filter in soapy water, then rinse and let dry.
MAINTENANCE Breather Filter/Hose The breather filter is on the hose that runs 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.
MAINTENANCE Fuse Replacement Fuse Feature Supported Speedometer (Main Fuse) Ignition, Lighting Accessories, 12V Power Receptacle If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Spare fuses are provided in the rear storage box.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean head- lights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fin- gers.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft.
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.
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. Harness 4.
Refer to the specifications section beginning on page 124 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft.
MAINTENANCE 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. The tip should not be flaky and white.
The camber and caster are non-adjust- able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Tip: Accessory springs are available through your POLARIS dealer. Adjuster...
Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.
MAINTENANCE Carburetor Your POLARIS ATV is calibrated at the factory for optimal perfor- mance at altitudes ranging from zero to 6,000 feet (1800 m) and temper- atures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800...
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.
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. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester 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.
• 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.
MAINTENANCE PVT System PVT Operation 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 fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt.
MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the tempera- ture inside the clutch cover greatly extends the life of the PVT compo- nents (belt, cover, etc.).
MAINTENANCE Battery WARNING 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. WARNING Battery electrolyte is poisonous.
MAINTENANCE Battery Battery Removal 1. Remove the battery hold-down strap. 2. Remove the battery cover. 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6.
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 can also hinder vehicle performance. Follow the battery charging instructions on page 111 before installing the battery.
POLARIS recommends maintaining battery charge 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.
MAINTENANCE 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 108. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
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.
MAINTENANCE 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.
113. 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 recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
6. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline. 7. To eliminate any fuel remaining in the carburetor, run the engine...
Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensa- tion, and may promote corrosion and oxidation.
MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.
PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Overuse of choke Inspect, clean and/or replace spark plugs Low battery voltage Recharge the battery to 12.8 VDC...
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug(s)
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect, clean and/or replace spark plugs Water is present in fuel Replace with new fuel Fouled or defective spark plug(s)
Warranty period will vary regionally. POLARIS also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
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 ATV that...
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA- TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehi- cle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...