Polaris Sportsman 9921818 Owner'S Manual Download Page 106 | Manualshive

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103

MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 60.

Battery Storage

See pages 95-96 for storage and charging procedures.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine Polaris cover. Do not use plastic or coated mate-
rials. They do not allow enough ventilation to prevent condensation, and
may promote corrosion and oxidation.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso-
ries. Accessory outlets are available for all models. Polaris also has a
wide range of additional accessories available for your ATV. Always
install accessories that are approved for ATV use. Please see your
Polaris dealer.

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Summary of Contents for Sportsman 9921818

Page 1: ......

Page 2: ...2...

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: ...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 abou...

Page 5: ...nd 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...

Page 6: ...troduction 4 Safety 7 Features and Controls 26 Operation 39 Emission Control Systems 59 Maintenance 60 Adjustments 105 Polaris Products 109 Troubleshooting 110 Specifications 114 Warranty 116 Maintena...

Page 7: ...l injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may...

Page 8: ...ty warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a new...

Page 9: ...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 ___________________________________________________ F...

Page 10: ...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 A...

Page 11: ...eds 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 m...

Page 12: ...protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris A...

Page 13: ...properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never...

Page 14: ...e off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run...

Page 15: ...ts properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perce...

Page 16: ...sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road...

Page 17: ...ng improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Ne...

Page 18: ...a hill Shift 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 hil...

Page 19: ...e owner s manual See page 52 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradual...

Page 20: ...slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in...

Page 21: ...Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with im...

Page 22: ...a caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the...

Page 23: ...argo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never opera...

Page 24: ...disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot compone...

Page 25: ...the label General Warning WARNING Improper 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 WIT...

Page 26: ...ATV on HILLS steeper than 25 degrees 25 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering be...

Page 27: ...8 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 5 0 psi 34 5 kPa Rear...

Page 28: ...ent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious inju...

Page 29: ...ctivation of All Wheel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 37 Engine Stop Switch Move the stop switch...

Page 30: ...ever for free movement and return before starting the engine Also check occasionally during operation Modifications to the electronic throttle control could result in failure to perform as designed wh...

Page 31: ...the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel a...

Page 32: ...unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking...

Page 33: ...rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Shou...

Page 34: ...ould result in an accident After opening a bottle of brake fluid always discard any unused portion Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the r...

Page 35: ...through the indicator win dow eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed...

Page 36: ...el tank Use either leaded or unleaded gaso line with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the...

Page 37: ...Neutral R Reverse To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is mo...

Page 38: ...st until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repe...

Page 39: ...ion of AWD in reverse if the AWD switch is on See page 26 Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the...

Page 40: ...luding insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Imm...

Page 41: ...Tip If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the A...

Page 42: ...ponents will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts an...

Page 43: ...he 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 43 6 Pull only light loa...

Page 44: ...d visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operat...

Page 45: ...icle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and alwa...

Page 46: ...ondition and pressure 79 Wheels fasteners Inspect ensure fastener tightness 79 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 33 67 Coolant level if applicabl...

Page 47: ...engine Excessive use of the choke can cause the spark plug to become wet fouled 6 If the engine is cold pull the choke knob out until it stops Tip The variable choke is fully on when the knob is pull...

Page 48: ...ver choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions a...

Page 49: ...n 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...

Page 50: ...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 tech nique alters the balance of trac tion between the rear whee...

Page 51: ...e traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to...

Page 52: ...hills 25 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight up...

Page 53: ...ssing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Shift body weight uphill 4...

Page 54: ...p hills 25 maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the brake lever gradually Applying the b...

Page 55: ...ointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your...

Page 56: ...case oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicl...

Page 57: ...ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfami...

Page 58: ...6 Never open the throttle suddenly 7 Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly in...

Page 59: ...racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could r...

Page 60: ...hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed t...

Page 61: ...oid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the dow...

Page 62: ...cess 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 ex...

Page 63: ...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 approx...

Page 64: ...ous injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use E Emission related...

Page 65: ...s fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X Air box sediment tube Daily Drain deposits when visibl...

Page 66: ...ect adjust replace as needed X Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at 20 hours X Oil filter change 100 H 6 M 1000 1600 Replace with oil change X Oil tank vent hose if e...

Page 67: ...hever comes first Remarks Hours Calendar Miles Km Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as neede...

Page 68: ...rake Fluid DOT 4 Only See page 31 Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 70 Front Demand Drive Unit Front Gearcase Premium Demand Drive Hub Fluid See page 73 Front Prop Shaft Yo...

Page 69: ...if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engi...

Page 70: ...ion in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for 30 seconds Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Re...

Page 71: ...brake 4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen...

Page 72: ...l the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand 15 Remove the dipstick 16 Add the recommended oil See page 66 17 Reinstall the dipstick 18 Start the engine A...

Page 73: ...le See page 109 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located behind the wheel well Tra...

Page 74: ...le on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Check the oil level 6 Add oil as needed Do not overfill 7 Reinstall the fill...

Page 75: ...wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use a 15 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 70 fo...

Page 76: ...of compo nents See page 109 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drai...

Page 77: ...l surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Check the oil level 6 Add the recommended oil as needed to bring the level to the...

Page 78: ...move the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug...

Page 79: ...mmended to keep the brake system 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 31 2 Check the b...

Page 80: ...position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straig...

Page 81: ...dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal 1 Remove the two screws on the...

Page 82: ...manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 114 for recom mended tire type size and...

Page 83: ...sion in gear 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your Polaris dealer 5 Place a suitable stand under the foot...

Page 84: ...orque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specif...

Page 85: ...water then rinse and let dry 9 Remove the breather filter 10 Wash the breather filter in soapy water then rinse and let dry 11 Reinstall the breather filter NOTICE Operation of your vehicle without a...

Page 86: ...3 Lock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start th...

Page 87: ...Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly CAUTION Hot components can cause burns to skin Allow lamps to cool before servici...

Page 88: ...ng is completely dry before reinstalling the drain plug 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine 4 Remove the drain screw on the bottom of the recoil housing 5 Reins...

Page 89: ...iring end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 87 CAUTION A hot exhaust system and...

Page 90: ...ctrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused...

Page 91: ...air box and replace the filter with a new filter 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 Turn the engine over several times using the electric start 7 Dr...

Page 92: ...he vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake 4 Remove the arrestor clean out plug from the bottom of the muffler 5 Start the engine 6 Quickly squeeze and...

Page 93: ...oads 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...

Page 94: ...Allow the water to drain com pletely Reinstall the drain plug 4 Start the engine Place the trans mission in neutral 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the bel...

Page 95: ...duce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV m...

Page 96: ...ve the battery vent tube 6 Disconnect the black negative battery cable first 7 Disconnect the red positive battery cable last 8 Lift the battery out of the ATV Be careful not to tip a conventional bat...

Page 97: ...tions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cau...

Page 98: ...ry 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...

Page 99: ...the 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...

Page 100: ...dard 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...

Page 101: ...to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body fi...

Page 102: ...ler to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any wat...

Page 103: ...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 periodical...

Page 104: ...instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow...

Page 105: ...e machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug Torqu...

Page 106: ...lightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to preven...

Page 107: ...ission in gear 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the ATV to the t...

Page 108: ...justments The front and rear shock absorber springs are adjustable Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension Always adjust both sides equally Acce...

Page 109: ...ol and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height 3 Be sure...

Page 110: ...your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause po...

Page 111: ...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 While adjusting...

Page 112: ...2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season...

Page 113: ...ge only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engag...

Page 114: ...l valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop swit...

Page 115: ...tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended...

Page 116: ...e Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel...

Page 117: ...ked Trailer Towing Capacity 1213 lbs 550 kg Overall Length 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radi...

Page 118: ...ghts 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Tripmeter Hourmeter Standard Fuel Gauge Standard Tool Kit Standard ALTITUDE Me...

Page 119: ...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 120: ...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 121: ...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 ad...

Page 122: ...ling 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 Co...

Page 123: ...ed 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 Ve...

Page 124: ...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...

Page 125: ...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 TECH...

Page 126: ...123 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

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