Polaris Sportsman 9921822 Owner'S Manual Download Page 71

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 59. Maintain the
oil level at the bottom of the fill plug hole. 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.

Transmission Oil Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Transmission

Premium AGL Synthetic

Gearcase Lubricant

20.3 oz.

(600 ml)

15 ft. lbs.

(20 Nm)

15 ft. lbs.

(20 Nm)

Drain Plug

Fill Plug

Summary of Contents for Sportsman 9921822

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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: ...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 38 Emission Control Systems 58 Maintenance 59 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: ...ATH 7175378 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...

Page 28: ...or hitch Max Rack Loads Front 70 lbs 32 kg Rear 100 lbs 46 kg 7173740 Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death D...

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 36 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: ...ays 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 Should the main system fail use the auxi...

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: ...are straight 2 View the fluid level 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...

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: ...vehicle may remain in AWD 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 AWD until the engine RPM is belo...

Page 39: ...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 40: ...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 41: ...of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a n...

Page 42: ...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 42 6 Pull only light loa...

Page 43: ...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 44: ...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 45: ...ition 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 65 Coolant level if applicable E...

Page 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 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: ...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 62: ...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 63: ...all services at whichever maintenance interval is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Q Steering Pre Ride Make adjustments as need ed See Pre...

Page 64: ...prior to storage Q E Throttle Cable ETC Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary Q E Choke cable 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Carbureto...

Page 65: ...Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect Q E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Q E Ignition Timing 100 H 12 M 1000 1600 Inspect X Wiring 100 H 12 M 1000 1600 Inspect...

Page 66: ...rake Fluid DOT 4 Only See page 31 Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 68 Front Demand Drive Unit Front Gearcase Premium Demand Drive Hub Fluid See page 71 Front Prop Shaft Yo...

Page 67: ...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 68: ...away all dirt and debris on the oil tank or in the wheel well area 5 Start the engine Allow it to idle for 30 seconds Stop the engine 6 Remove the dipstick Wipe it dry with a clean cloth 7 Reinstall t...

Page 69: ...ty of the engine sump and oil tank combined is 2 25 qts 2 1 liters 1 Position the vehicle on a level sur face 2 Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it t...

Page 70: ...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 64 17 Reinstall the dipstick 18 Start the engine A...

Page 71: ...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 72: ...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 73: ...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 68 fo...

Page 74: ...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 75: ...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 76: ...ve the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 8mm Allen wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plu...

Page 77: ...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...

Page 78: ...run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool befor...

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: ...and remove the filter 6 Remove the fabric type pre fil ter from the main filter Wash the pre filter in soapy water then rinse and let dry 7 Reinstall the pre filter over the main filter Install a new...

Page 86: ...the direction of the arrow to check for clogging Replace a damaged or clogged filter 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and hose clamps...

Page 87: ...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 88: ...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 89: ...s Immediately check the spark plug for correct color See page 87 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the s...

Page 90: ...hould not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator ti...

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: ...5 Remove the battery cover 6 On conventional batteries remove the battery vent tube 7 Disconnect the black negative battery cable first 8 Disconnect the red positive battery cable last 9 Lift and remo...

Page 97: ...he 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 cause an explosion resulting in serious...

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: ...installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully cha...

Page 100: ...y volt age is 12 8 or greater When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for rec...

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: ...s off con tact your Polaris dealer 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 f...

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: ...tabilizer Follow the 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 exh...

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: ...uid 2 5 gal 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 3 oz 2871322 Premium All Season Grease 3 oz ca...

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: ...ltage 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 t...

Page 117: ...45 kg Hitch Towing Rating 750 lbs 340 2 kg Unbraked Trailer Towing Capacity 1786 lbs 810 kg Overall Length 73 in 185 cm Overall Width 44 in 112 cm Overall Height 46 in 117 cm Wheelbase 46 in 117 cm Gr...

Page 118: ...lic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Dual Beam on Bumper 37 5 watt Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12...

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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