Polaris Sportsman 9921483 Owner'S Manual Download

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155

Maintenance

Drive Chain Slack Adjustment

1. Loosen the four rear housing mount bolts.
2. Loosen the chain adjuster lock nut.
3. Turn the chain adjuster clockwise to 1/4"-1/2"

(6-12 mm) deflection.

4. Tighten the chain adjuster lock nut to 18 ft. lbs.

(25 Nm).

5. Tighten the four rear housing mount bolts to 43

ft. lbs. (60 Nm).

CAUTION

Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud.

Housing

Mount

Bolts

Chain Adjuster

Summary of Contents for Sportsman 9921483

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Page 3: ...r 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 WARNING The engine exhaust from this product contains chemicals known to...

Page 4: ...1 Visit us at www polarisindustries com...

Page 5: ...ality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are int...

Page 6: ...ldren differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Always supervise your child s use of the ATV and permit continued use only if you determi...

Page 7: ...the information in your owner s manual Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others...

Page 8: ...ecals 34 Driver Warnings 43 Vehicle ID Numbers 66 Features and Controls 67 Break in Period 83 Pre Ride Inspections 85 Starting the Engine 88 Stopping the Engine 91 Driving Safely 92 Emission Control 1...

Page 9: ...roved ATV safety training course such as the SVIA RiderCoursesm and understand all warnings and the owner s manual before driving the ATV Know Your ATV Before Riding Parents must help their children l...

Page 10: ...and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm In addition you were provided with printed material and a video or DVD that instructs oper ators on safe...

Page 11: ...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 ale...

Page 12: ...us 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...

Page 13: ...age and Y 6 50cc models are designed for children not less than 6 years of age No child under the age of 16 should ride any ATV designed and sold for an adult Do not allow other children to ride this...

Page 14: ...your experience Never attempt jumps or other stunts Never tow or pull an object behind the ATV Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow...

Page 15: ...limbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open th...

Page 16: ...p hill Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special...

Page 17: ...urns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dr...

Page 18: ...oses Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipme...

Page 19: ...16...

Page 20: ...17 Youth Section...

Page 21: ...ifications section beginning on page 178 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know Your safety and the safety of other...

Page 22: ...to shut the engine off quickly The button must be up before you can start the engine again 2 Horn Button Press the horn button to sound the horn 3 Throttle Control Press the throttle lever with your t...

Page 23: ...own on the kick start lever with your foot to start the engine Have an adult show you how it works Read more about how to use the kick start on page 82 5 Shift Lever The shift lever is on the right si...

Page 24: ...have an adult put gas in your ATV Never try to do it yourself 7 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the...

Page 25: ...s the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and b...

Page 26: ...hed snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never ride without the tether stra...

Page 27: ...24 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off...

Page 28: ...t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close t...

Page 29: ...e your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you...

Page 30: ...heck the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks n This last check is done with the engine running You must check to make sure that all...

Page 31: ...riving an ATV Adults have riding rules too The rules help keep us safe when we ride X The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always d...

Page 32: ...s to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from...

Page 33: ...he ATV harder to drive You may lose control and hurt yourself and your passenger X Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests X Alwa...

Page 34: ...ght Your ATV doesn t have lights that are safe for driving in the dark X Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them X Never ride on frozen water You...

Page 35: ...32 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new Polaris ATV...

Page 36: ...33 Adult Section...

Page 37: ...any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Pola...

Page 38: ...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 increase risk of losing control ALWAYS use prop...

Page 39: ...quired Make sure operators follow Owner s Manual and labels Make sure operators watch the safety video or DVD and complete the ATV RiderCoursesm Never operate this ATV on HILLS steeper than 15 degrees...

Page 40: ...NING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 3 20 7 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight...

Page 41: ...240 KG Reduce speed and allow greater distance for braking when carrying cargo Overloading or carry ing tall off center or unsecured loads will increase your risk of losing control Loads should be cen...

Page 42: ...39 Safety Decals No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH...

Page 43: ...Safety Decals Sportsman 90 Rack Warning WARNING DO NOT TOW WITH THIS VEHICLE Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 lbs 6 8 kg Rear 30 lbs 13 6...

Page 44: ...lt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause part failure possib...

Page 45: ...42...

Page 46: ...o read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your child s safety Be sure to explain to your young driver that the following hazards...

Page 47: ...ations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then regula...

Page 48: ...commended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities...

Page 49: ...duces your ability to balance and control this ATV Carrying a passenger could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpo...

Page 50: ...HAT CAN HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Av...

Page 51: ...ublic streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any paved or unpaved public street road or highway In many states...

Page 52: ...t increases the risk of a severe head injury or death in the event of an acci dent Operating without eye protection and protective clothing can also result in injury HOW TO AVOID THE HAZARD Always wea...

Page 53: ...onsuming alcohol or drugs WHAT CAN HAPPEN Your judgment could be seriously affected You may react more slowly Your balance and perception will be affected You could have an accident HOW TO AVOID THE H...

Page 54: ...visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibil...

Page 55: ...L HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other stunts Avoid...

Page 56: ...foot can make it harder to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may touch the rear wheels which could i...

Page 57: ...in WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of control HOW TO AVOID THE HAZARD Go slowly and be extra c...

Page 58: ...sively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slipper...

Page 59: ...n the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV WHAT C...

Page 60: ...lls as described in the Owner s Manual beginning on page 98 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your wei...

Page 61: ...ocedures for going down hills as described in the Owner s Manual See page 104 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start d...

Page 62: ...urn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 102 Use extra caution when turning on any hill Avoid crossing the...

Page 63: ...es gradually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If you begin rolling backwards Keep weight uphill Never apply engine power Never app...

Page 64: ...ra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control...

Page 65: ...WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pre...

Page 66: ...ough deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 106 travel slowly balance your weight carefully avoid sudden movements and mainta...

Page 67: ...WARNING POTENTIAL HAZARD Operating the ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or modifi cation of the ATV may cause changes in han dling which could lea...

Page 68: ...alified ser vice dealer check the complete vehicle includ ing but not limited to brakes throttle and steering for possible damage WARNING Hot components can cause serious burns Do not touch hot exhaus...

Page 69: ...with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame VIN ___________...

Page 70: ...To avoid draining the battery always turn the key to the OFF position when the engine is not running WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in s...

Page 71: ...r emergency NOTE Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Use the choke to s...

Page 72: ...htly above the choke lever 1 Attach the tether strap securely to the vehicle and to the rider s right wrist 2 Shift the transmission to neutral The neutral light will come on when the lever is in neu...

Page 73: ...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 syst...

Page 74: ...ned to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear whe...

Page 75: ...e desired gear Do not try to shift gears with engine speed above idle or while the ATV is mov ing Maintaining shift linkage adjustment is important to assure proper transmission function See your deal...

Page 76: ...hile the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Always place the transmission in gear with the parking brake...

Page 77: ...the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious i...

Page 78: ...parking brake lock squeeze and release the brake lever The parking brake will release automatically WARNING Operating the ATV while the parking brake is engaged could cause an accident resulting in se...

Page 79: ...on to neutral and lock the parking brake before starting the engine 2 After the engine has warmed enough for operation shift to the desired gear 3 Release the parking brake and gently apply the thrott...

Page 80: ...laris Youth ATVs are not equipped with lights that are designed for driving in the dark Do not operate this ATV after dark Use caution and drive at reduced speeds in conditions of reduced visi bility...

Page 81: ...flames or sparks in or near the area where refueling is per formed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediatel...

Page 82: ...nd Controls Fuel System WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ven...

Page 83: ...l System Gas Cap The fuel tank filler cap is located directly below the handlebars Use unleaded gasoline with a minimum pump octane of 87 Refer to the specifications sec tion beginning on page 178 for...

Page 84: ...orting ON For normal operation RES For reserve supply if main supply is exhausted NOTE The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill the gas tank as soon as...

Page 85: ...the left side of the ATV NOTE A 10 12mm wrench is provided in the tool kit for removing or installing the lever If not installed make sure the rubber cap is on the kick start shaft to protect the ride...

Page 86: ...nt of a new engine will result in more efficient performance and longer life for the engine Per form the following procedures carefully CAUTION Excessive heat build up during the first three hours of...

Page 87: ...dling 4 Vary 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 85 6 Perform t...

Page 88: ...t the ATV before each use to ensure it s in proper operating condition Pre Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 145 149 Front suspension Inspect lubricate...

Page 89: ...sure fastener tightness check that axle nuts are secured by cot ter pins 161 162 Fuel and oil Check and fill as needed 78 80 Throttle Check for proper operation 25 70 71 Engine stop switch Check for p...

Page 90: ...ean or replace 156 Drive chain Check condition and slack refer to drive chain adjustment 153 Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any da...

Page 91: ...on monoxide and can cause loss of consciousness result ing in severe injury or death Never run an engine in an enclosed area CAUTION Operating the ATV immediately after starting could cause engine dam...

Page 92: ...tely to the left The choke is off when the lever is pushed completely to the right The choke can be adjusted gradually depending on how much choke is needed for starting 5 If the engine is cold use fu...

Page 93: ...eleasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts 10 If the engine slows or sto...

Page 94: ...s to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV NOTE To avoid draining the battery always turn the key to the OFF position when the engine is n...

Page 95: ...ets or exceeds 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 labe...

Page 96: ...rsonal 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...

Page 97: ...engine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Squeeze the left brake lever 6 Shift the transmission to the desired gear 7 Slowly release the brake lever...

Page 98: ...ction slightly To turn steer in the direction 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 trac...

Page 99: ...e care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on exc...

Page 100: ...vel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause s...

Page 101: ...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 15 maximum Use extreme caution when operati...

Page 102: ...travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the footrests 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be pr...

Page 103: ...ARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper...

Page 104: ...tion where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep ing your feet on the footrests 3 Steer slightly into...

Page 105: ...ntaining body weight uphill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill WARNING Imp...

Page 106: ...o roll around to your right until it s pointing across the hill or slightly downward 7 Lock the parking brake and remount the ATV from the uphill side maintaining body weight uphill 8 Restart the engi...

Page 107: ...irectly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the front and rear brakes at the same time and very slightly to aid in slowing WARNING Excessive speed can cause...

Page 108: ...Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown...

Page 109: ...ugh water 1 Determine water depths before driving through water 2 If crossing a stream choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possibl...

Page 110: ...nance chart beginning on page 114 The following areas need special attention engine oil gearcase oil front and rear gearcases if equipped and all grease fittings CAUTION Major engine damage can resul...

Page 111: ...r rain you re traveling on Be constantly alert for hazards such as logs rocks and low hang ing branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacl...

Page 112: ...cking downhill 5 Never open the throttle suddenly while backing 6 Always look left right and behind the ATV before backing WARNING Failure to use caution when operating in reverse can result in seriou...

Page 113: ...Outlaw 90 Place 1 3 of the cargo weight on the front rack and 2 3 on the rear rack Carrying loads on only one rack increases the chance of a tipover Slow down Allow more space for stopping the ATV whe...

Page 114: ...s or rope to secure the cargo Do not allow cargo or tie straps to hang over the edges of the racks Carry only small loads that fit on the racks Tall loads raise the center of gravity of the vehicle an...

Page 115: ...e USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public...

Page 116: ...at the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or engine case near the clutch box NOTE The install...

Page 117: ...tment under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe...

Page 118: ...rts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Sev...

Page 119: ...on from grease fittings and other critical components E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions Q Dealer service ite...

Page 120: ...re Ride Check list 85 X Front suspension Daily X Rear suspension Daily Tires Daily X Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily X Engine oil level Daily X...

Page 121: ...t and lubricate if needed 153 CVT housing if equipped Weekly Drain water as needed check often if operating in wet conditions 137 Break in Maintenance After first 10 hours of operation Perform break i...

Page 122: ...filter screen 40 12 M 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours 127 X General lubrication 50 3 M 500 800 Lubricate all fittings pivots cables etc QE...

Page 123: ...r air intake ducts flange 50 6 M 500 800 Check for proper sealing air leaks Q Drive belt 50 6 M 500 800 See your Polaris dealer XQ Brake pad wear 50 6 M 500 800 See your Polaris dealer QE Fuel system...

Page 124: ...ect for wear routing security apply dielectric grease to connec tors subjected to water mud etc Q Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 1...

Page 125: ...c Youth Oil or Synthetic SAE 40 See page 124 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 130 Drive Chain Polaris Chain Lube or SAE 80 90 See page 153 X Front Suspensio...

Page 126: ...123 Maintenance Lubrication Guide Grease Points Grease Points...

Page 127: ...not use automotive oil See page 182 for the part numbers of Polaris products Under These Operating Conditions Use This Recommended Oil Outside air temperature is above 32 F 0 C Polaris Synthetic Yout...

Page 128: ...an cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moist...

Page 129: ...vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause serious burns to skin Do...

Page 130: ...tely 7 Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry 8 Clean the pre filter plug Install a new sealing washer on the plug NOTE The sealing surfaces on the pl...

Page 131: ...ended oil Do not overfill NOTE See the specifications section beginning on page 178 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the eng...

Page 132: ...The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 114 Do not attem...

Page 133: ...hange the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 182 for the part numbers of Pola...

Page 134: ...e the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fill plug hole t...

Page 135: ...dition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION Using non recommended spark plugs...

Page 136: ...tor throttle body adjustments Wet Fouled 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...

Page 137: ...starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Turn the fuel valve off 3 Check the air box for any water and dry it if wate...

Page 138: ...e it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as...

Page 139: ...ration and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the...

Page 140: ...on to neutral 3 Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 4 Allow th...

Page 141: ...beginning on page 114 WARNING Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool suf...

Page 142: ...synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage R...

Page 143: ...h 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available fr...

Page 144: ...rbure tor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw either in or out until the desired idl...

Page 145: ...either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable throttle limiting screw Speed limiting devices may be ad...

Page 146: ...ottle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten th...

Page 147: ...le for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay fa...

Page 148: ...the intervals rec ommended in the Periodic Maintenance Chart beginning on page 114 If the freeplay isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specific...

Page 149: ...e front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground 4 While rotating the left front wheel tighten the upper front brake adjuster nut on...

Page 150: ...ront brake adjuster nut on the right hand control 7 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 8 Verify that the right hand brake functions correctly...

Page 151: ...rear tires should be slightly off the ground 4 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 5 When you begin to feel a slight drag in wheel rota tion loosen t...

Page 152: ...on the preceding pages use the following information to determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table...

Page 153: ...eering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands in front of the vehicle perpendicular to...

Page 154: ...on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear mea surement should be 1 1...

Page 155: ...ave your dealer tighten them before operating the ATV Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The front and rear shock absorber springs are adjustable to inc...

Page 156: ...wet conditions See page 182 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t use...

Page 157: ...he strap around the axle and rear bumper tube 3 Tighten the strap until a straight line can be drawn from the rear axle to the gearcase output shaft intersecting the swing arm pivot This establishes t...

Page 158: ...nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft lbs 25 Nm 5 Tighten the four rear housing mount bolts to 43 ft lbs 60 Nm CAUTION Ho...

Page 159: ...ing clips and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply a commercially av...

Page 160: ...or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat CAUTION Never operate the ATV with the filter element removed Dirt will enter the engine cau...

Page 161: ...icle when turned fully to the left or right 3 Lightly tighten each bolt equally to prevent uneven gaps in the block Torque the bolts to 7 3 ft lbs 10 Nm WARNING Improper adjustment of the handlebars o...

Page 162: ...vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equi...

Page 163: ...worn to 1 8 3 mm or less Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest...

Page 164: ...n the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Install the wheel bolts and finger tighten them 4 L...

Page 165: ...h a cotter pin installed must be service by an authorized Polaris dealer Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must...

Page 166: ...doesn t work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the lamp and replace it with a new recommended lamp 3 Test the light for p...

Page 167: ...er or pod to access the lamps 2 Remove the indicator wire connections from the harness 3 Remove the nut from the back side of the indicator lamp 4 Remove the lamp 5 Apply dielectric grease to the sock...

Page 168: ...he light assembly 4 Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out 5 Install the new lamp Mak...

Page 169: ...ire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly...

Page 170: ...y Removal 1 Disconnect the hold down straps securing the electrical box and battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 L...

Page 171: ...rged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary...

Page 172: ...life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect rep...

Page 173: ...lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power w...

Page 174: ...Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals NOTE If warning and safety labels are damaged contact y...

Page 175: ...sh 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 vehi cle Always use clean cloths an...

Page 176: ...he vehicle as recommended See page 169 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each mon...

Page 177: ...period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount NOTE Carbon clean will also reduce...

Page 178: ...r Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintena...

Page 179: ...sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated...

Page 180: ...Secure the fuel cap oil cap and seat 5 Turn the fuel valve off 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not off...

Page 181: ...4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gallons 6 4 liters Fuel Reserve Capacity 23 gallons 86 liters Starting Electric with kick start backup Drive System Automatic...

Page 182: ...ock Front Tires 19 x 7 8 3 psi Rear Tires 18 x 9 5 8 3 psi Dry Weight 270 lbs 122 4 kg Length Width Height 61 25 156 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing...

Page 183: ...ype 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 2 gallons 7 7 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automati...

Page 184: ...rakes Drum Parking Brake Mechanical Lock Front Tires 19 x 7 8 3 psi Rear Tires 18 x 9 5 8 3 psi Dry Weight 289 lbs 131 kg Length Width Height 61 75 157 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm...

Page 185: ...th Oil qt 95 l 2876249 Synthetic Youth Oil gal 3 8 l 2872175 Semi Synthetic 20W 40 Oil qt 95 l 2872176 Semi Synthetic 20W 40 Oil gal 3 8 l 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants...

Page 186: ...183 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease 3 oz 89 ml 2871423 All Season Premium Grease 14 oz 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus...

Page 187: ...system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spa...

Page 188: ...charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octane fuel Replace with r...

Page 189: ...ugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect...

Page 190: ...e Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with 5 amp charger Kin...

Page 191: ...el clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of...

Page 192: ...plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conne...

Page 193: ...laris 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 re...

Page 194: ...osion 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...

Page 195: ...OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Som...

Page 196: ...form warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warra...

Page 197: ...s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorize...

Page 198: ...country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be d...

Page 199: ...rements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date This emission related...

Page 200: ...N TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above l...

Page 201: ...to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED...

Page 202: ...199 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours...

Page 203: ...200 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 204: ...201 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 205: ...rying 137 CVT System 136 Cylinder Head Torque 134 D Daytime Running Lights 165 Drive Chain 153 Drive Chain Slack 154 Drive Chain Slack Adjustment 155 Driving Across Hillsides 100 101 Driving Downhill...

Page 206: ...smission 130 Oil Engine 124 Operation Warning 35 P Parking on a Hill or Incline 105 Passenger Warning 39 Periodic Maintenance Chart 114 121 Polaris Products 182 Polishing 172 Pre Ride Inspection 85 87...

Page 207: ...Lever 71 Throttle Stop Speed Control System 143 Tire Pressure Warning Outlaw 90 37 Sportsman 90 38 Tire Tread Depth 160 Tires 159 Toe Alignment 150 151 Transmission Oil 130 131 Transporting the ATV 17...

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Polaris Sportsman 9921483, Owner'S Manual

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