Polaris Sportsman 9921169 Owner'S Manual Download

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SAFETY

Operator Safety

WARNING

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.

WARNING

Safe operation of this rider-active vehicle requires good judgement and

physical skills. Persons with cognitive or physical disabilities who operate this

vehicle have an increased risk of overturn and loss of control, which could

result in severe injury or death.

WARNING

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause serious burns and fire. Do not touch hot exhaust

system components. Always keep combustible materials away from the

exhaust system. Use caution when traveling through tall grass, especially dry

grass.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle

resulting in serious injury or death. Always remove the ignition key when the

vehicle is not in use.

Summary of Contents for Sportsman 9921169

Page 1: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 2: ...d quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is e...

Page 3: ...w Your Vehicle 5 Safety 6 Features and Controls 34 Operation 54 Emission Control Systems 71 Maintenance 72 Adjustments 120 Troubleshooting 122 Polaris Products 126 Specifications 127 Warranty 129 Maintenance Log 135 Index 138 ...

Page 4: ...4 ...

Page 5: ... 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 The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _______________________________________________...

Page 6: ...ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and...

Page 7: ...G 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 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 515 LBS 234 KG INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of l...

Page 8: ...ause a loss of control resulting in SEVERE INJURY or DEATH 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 No Passenger Warning Clutch Cover Warning Age 16 Warning Rack Warning Rack Warning ...

Page 9: ... severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 100 lbs 45 kg Rear 200 lbs 91 kg Reverse Override Warning WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in 4X4 AWD See Owner s Manual All Wheel Drive Switch Do not push switch to engage 4X4...

Page 10: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 11: ...ersonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a je...

Page 12: ...n 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 collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operatin...

Page 13: ...ing procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operati...

Page 14: ...rt symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note ...

Page 15: ...perate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the ...

Page 16: ...g or descending a hill Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always move the 4X4 switch to ADC 4X4 before ascending or descendi...

Page 17: ...n Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp an...

Page 18: ... make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of c...

Page 19: ...se and the operating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a ...

Page 20: ... is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident...

Page 21: ... POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOI...

Page 22: ...operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE ...

Page 23: ...er stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures...

Page 24: ...ld contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn...

Page 25: ...te on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for ...

Page 26: ...THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 44 Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open ...

Page 27: ...t your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning on hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Neve...

Page 28: ... forward speed is lost Keep your weight uphill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if...

Page 29: ...les such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and...

Page 30: ... your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Th...

Page 31: ...bed in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehi...

Page 32: ...ity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operato...

Page 33: ...sabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling ...

Page 34: ... This switch is also used to toggle through the modes of the rider information center See page 45 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 44 WARNING 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 Work Light ...

Page 35: ... at the rear of the vehicle Turn the light on while loading and unloading cargo in low light situations Turn the work light off when driving Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position WARNING Operating the...

Page 36: ...hrottle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free moveme...

Page 37: ...ravel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the...

Page 38: ...luid only See page 126 for the part numbers of Polaris products WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture cause...

Page 39: ...portant Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling WARNING Operat...

Page 40: ... wheels with out skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat Maintain the fluid level between the maximum and minimum marks WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when...

Page 41: ... Gear N Neutral R Reverse P Park Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transm...

Page 42: ...hen the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 NOTE The override switch allows act...

Page 43: ...f the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 CAUTION Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gea...

Page 44: ...follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 po...

Page 45: ...tion NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not ...

Page 46: ...Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge The segme...

Page 47: ...reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is ...

Page 48: ... as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Press and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly ...

Page 49: ...r all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each t...

Page 50: ... button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle Th...

Page 51: ...tions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END...

Page 52: ...ump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery volt...

Page 53: ...Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to ...

Page 54: ...ed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING The engine exhaust from this product contains che...

Page 55: ...yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 56 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clu...

Page 56: ...asteners Inspect ensure fastener tightness 93 94 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 41 79 Coolant level if applicable Ensure proper level 88 89 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 36 121 Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pre filter Inspe...

Page 57: ...another five seconds if necessary Repeat this procedure until the engine starts Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increa...

Page 58: ...ons Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combina tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity CAUTION Using an improper hitch or ex...

Page 59: ...oads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme ...

Page 60: ...ands on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 61: ...n of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp an...

Page 62: ...urning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire...

Page 63: ... Proceed at a steady rate of speed and throttle opening 7 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution w...

Page 64: ... your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately WARNING 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 poss...

Page 65: ...w down 5 Squeeze the brake lever gradually NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if service brakes become inoperable WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious i...

Page 66: ... the vehicle or on the left if the vehi cle is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake and remount the vehicle from the uphill side keeping body we...

Page 67: ...r gearcase oil and all grease fittings NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s...

Page 68: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 69: ... increased Do not operate at wide open throttle WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and...

Page 70: ...rking 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 ...

Page 71: ...ons are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine desi...

Page 72: ...service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high...

Page 73: ...ted service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 74: ...aily Inspect clean often replace as needed X Air box sediment tube Daily Drain deposits when visible Coolant if applicable Daily Check level daily change coolant every 2 years X ADC fluid ADC models Daily Check level daily add as needed Headlamp taillight work light Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed Recoil housin...

Page 75: ...system yearly X Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at one month X Oil filter change 100 H 6 M 1000 1600 Replace with oil change Q E Valve clearance 100 H 12 M 1000 1600 Inspect adjust Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years X Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces X Cooling ...

Page 76: ...H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed Q Brake fluid 200 H 24 M 2000 3200 Change every two years Q ADC fluid ADC models 200 H 24 M 2000 3200 Change every two years X Q E Fuel filter 200 H 24 M 2000 3200 Check for leaks around lines Replace every 2 years more often under extreme conditions Spark arrestor 300 H 36 M 300...

Page 77: ...user s discretion Item Lube Capacity at Fluid Change Inspection Procedure Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l See page 78 Brake Fluid DOT 4 Only See page 38 Transmission Oil Polaris AGL Synthetic Gearcase Lube 15 oz 450 ml See page 82 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid 9 3 oz 275 ml See page 83 ADC Fluid Polaris ADC Fluid See page 86 Rear Gearca...

Page 78: ...il 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 See page 126 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands ...

Page 79: ...e dipstick must be inserted completely to keep the angle and depth of the stick consis tent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick 5 After reinstalling the...

Page 80: ...for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely 7 Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 20 ft lbs 27 Nm CAUTION Ho...

Page 81: ...ck to make sure the o ring is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 13 Remove the dipstick 14 Add two quarts 1 9 l of recommended oil 15 Place the transmission in PARK 16 Lock the parking brake 17 Start the engine Allow it to idle for one to two minutes 18 Stop the engine ...

Page 82: ...page 126 for the part numbers of Polaris products Oil Check 1 Remove the footwell see page 92 2 Remove the fill plug Check the oil level 3 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 4 Reinstall the footwell Oil Change 1 Remove the footwell see page 92 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely 3 Clean and reinstall the drain plug Torque to...

Page 83: ...of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bot tom of the fill hole threads 3 Reinstall the fill plug Torque to 8 10 ft lbs 11 14 Nm Fluid Change 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the dr...

Page 84: ...n the rear of the gearcase The drain plug is located on the bottom of the gear case We recommend the use of Polaris ATV Angle Drive Fluid or GL5 80 90 weight gear lube See page 126 for the part numbers of Polaris prod ucts Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill h...

Page 85: ...e 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 5 Remove the fill plug Add 5 oz 150 ml of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 7 Check for leaks 8 Dispose of used oil properly ...

Page 86: ... page 72 Maintain the fluid level between the minimum and maximum marks on the reservoir We recom mend the use of Polaris ADC Fluid See page 126 for the part numbers of Polaris products NOTE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system 1 Open the front box cover and pull open the access door 2 View the fluid level in the reservoir 3 If the level is below...

Page 87: ...uid 5 Remove the protective caps from the bleeder valves 6 Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir wil...

Page 88: ...e system is purging itself of trapped air 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 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 ...

Page 89: ...iator Add coolant as needed 1 Open the front box cover and pull open the access door 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radia tor filler neck 4 Reinstall the pressure cap 5 Secure the access door 6 Secure the box cover NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacemen...

Page 90: ...tem in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 38 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condit...

Page 91: ... edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 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 yo...

Page 92: ...side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing ...

Page 93: ...arking brake 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain pro...

Page 94: ...ecification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Pol...

Page 95: ... as filter damage could occur 7 Reinstall the air box cover and the seat Fuse Replacement If the engine stops or will not start or if you experience other electrical failures a fuse may need replace ment Locate and correct any short circuits that may have caused the blown fuse then replace the fuse NOTE Spare fuses are provided in a compartment on the top of the access door 1 Open the front box co...

Page 96: ...nnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod WARNING Poor lighting while driving can result in s...

Page 97: ... the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 1 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low ...

Page 98: ...g harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the head lamp parting line to th...

Page 99: ...rness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Work Light if equipped Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counterclock wise to remove it 3 Apply dielectric grease to the socket and install the new lamp 4 Reinstall the harness connector 5 Test the light for...

Page 100: ... correct color See page 101 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs ...

Page 101: ...ne and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of ...

Page 102: ...over several times using the electric start 6 Dry the spark plugs Reinstall the plugs or install new plugs 7 Attempt to start the engine If necessary repeat the drying proce dure 8 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 9 If water has been ingested into the PVT follow the procedure on page 106 for drying out the PVT CAUTION If your veh...

Page 103: ... cm higher than the front Block the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Th...

Page 104: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owne...

Page 105: ... to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low t...

Page 106: ...K 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible ...

Page 107: ...th clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING 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 o...

Page 108: ...careful not to tip a conventional battery sideways which could spill electrolyte 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 CAUTION If electrolyte spills immediately wash...

Page 109: ...urely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Install the battery cover 8 Secure the battery hold down strap 9 Verify that cables are properly rout...

Page 110: ...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 See page 126 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained batte...

Page 111: ...e sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A f...

Page 112: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 113: ...ith a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish CAUTION High water pressure may damage c...

Page 114: ...ris 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 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 th...

Page 115: ...ent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pr...

Page 116: ...stems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 80 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Drain the sediment tube CAU...

Page 117: ...nutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of Premium 4 Syn thetic 0W40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of each spark plug c...

Page 118: ...e ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available ...

Page 119: ...ngine 2 Place the transmission in PARK 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 Do not attach tie straps to the front A arm bolt pockets 6 Remove the key to prevent loss during transporting ...

Page 120: ...r to the desired height NOTE Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tight...

Page 121: ... handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot...

Page 122: ... Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of contro...

Page 123: ... Fouled or defective spark plugs 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 Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug ga...

Page 124: ...inked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kin...

Page 125: ...ections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your d...

Page 126: ...and Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Premium U Joint Lube...

Page 127: ...Capacity 1914 lbs 868 kg Overall Length 83 in 211 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 50 75 in 128 9 cm Ground Clearance 11 25 in 28 5 cm Dry Weight 770 lbs 349 kg with cast wheels 780 lbs 354 kg with steel wheels Minimum Turning Radius 76 in 193 cm unloaded Engine EH0760LE Displacement 760 cc Bore x Stroke 80 x 76 Alternator Output 500 Watts 3000 rpm Compression Ra...

Page 128: ...rakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brakes Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Fee...

Page 129: ...olaris dealer 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed...

Page 130: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control 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 com ponents or products THE ...

Page 131: ...e your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the a...

Page 132: ...eling 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 Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 133: ...red outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 134: ... replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT ...

Page 135: ... 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 OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 136: ...136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 137: ...137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

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Polaris Sportsman 9921169, Owner'S Manual

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