Polaris Sportsman 9922051 Owner'S Manual Download Page 154

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150

INDEX

Parking Brake . . . . . . . . . . . . . . . . . 33

Parking on an Incline . . . . . . . . . . . . 71

Passenger Seat . . . . . . . . . . . . . . . 40-41

Periodic Maintenance Chart . . . . 77-80

Polaris Product List . . . . . . . . . . . . 133

Polishing the Vehicle. . . . . . . . . . . 124

Pre-Ride Checklist . . . . . . . . . . . . . . 54

PVT Break-In. . . . . . . . . . . . . . . . . . 53

PVT Drying . . . . . . . . . . . . . . . . . . 111

PVT System. . . . . . . . . . . . . . . 110-111

Rack/Compartment, Front . . . . . . . . 42

Reverse Operation . . . . . . . . . . . . . . 70

Reverse Override Switch . . . . . . . . . 28

Rider Information Center. . . . . . . 44-51

Riding Area . . . . . . . . . . . . . . . . . . . 56

Riding Gear . . . . . . . . . . . . . . . . . . . 8-9

Safe Operation Practices . . . . . . . . . 55

Safety Labels . . . . . . . . . . . . . . . 22-27

Age 16 Warning. . . . . . . . . . . . 23

AWD Caution . . . . . . . . . . . . . 23

Box Warning . . . . . . . . . . . . . . 27

Clutch Cover Warning. . . . . . . 26

Discretionary Warning. . . . . . . 24

General Warning . . . . . . . . . . . 22

Passenger Safety Warning . . . . 24

Rack Warning, Front and Rear 26

Reverse Override Warning . . . 23

Tire Pressure/Load Warning . . 25

Safety Training . . . . . . . . . . . . . . . . . 7

Safety Warnings. . . . . . . . . . . . . 10-21

Age Restrictions . . . . . . . . . . . 10

Carrying a Passenger . . . . . . . . 12

Carrying Multiple Passengers . 12

Crossing Hillsides . . . . . . . . . . 15

Deep Water . . . . . . . . . . . . . . . 19

Descending Hills Improperly. . 15

Excessive Speeds . . . . . . . . . . . 13

Exhaust Exposure . . . . . . . . . . 11

Failure to Inspect . . . . . . . . . . . 11

Safety Warnings

Frozen Bodies of Water. . . . . . . 20

Handling Gasoline . . . . . . . . . . . 11

Hot Exhaust Systems . . . . . . . . . 21

Improper Cargo Loading . . . . . . 19

Improper Hill Climbing . . . . . . . 15

Improper Tire Maintenance . . . . 18

Jumps and Stunts . . . . . . . . . . . . 14

Operating a Damaged ATV. . . . 21

Operating on Pavement . . . . . . . 13

Operating on Public Roads . . . . 13

Operating on Steep Hills . . . . . . 16

Operating Over Obstacles . . . . . 18

Operating Without Instruction. . 10

Passenger in the Cargo Box. . . . 13

Physical Control of the ATV . . . 14

Physical Skills . . . . . . . . . . . . . . 21

Poor Visibility . . . . . . . . . . . . . . 20

Protective Apparel . . . . . . . . . . . 12

Reverse Operation . . . . . . . . . . . 17

Skidding or Sliding . . . . . . . . . . 18

Slippery Terrain. . . . . . . . . . . . . 17

Stalling While Climbing a Hill . 16

Turning Improperly . . . . . . . . . . 14

Unauthorized Use . . . . . . . . . . . 21

Unfamiliar Terrain. . . . . . . . . . . 17

Using Alcohol or Drugs. . . . . . . 12

Seat Removal. . . . . . . . . . . . . . . . . . . 97

Severe Use . . . . . . . . . . . . . . . . . . . . . 77

Side Panel Removal. . . . . . . . . . . . . . 97

Sidehilling . . . . . . . . . . . . . . . . . . . . . 64

Signal Words . . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . . . 109

Spark Plug Inspection . . . . . . . 106-107

Spark Plug Recommendations. . . . . 106

Spark Plugs . . . . . . . . . . . . . . . 106-107

Spring Adjustment, Shock. . . . . . . . 121

Standard/Metric Display . . . . . . . . . . 47

Starting the Engine . . . . . . . . . . . . . . 57

Steering Assembly. . . . . . . . . . . . . . . 96

Storage . . . . . . . . . . . . . . . . . . . 123-128

Storage Tips. . . . . . . . . . . . . . . 126-128

Summary of Contents for Sportsman 9922051

Page 1: ......

Page 2: ...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 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...ER USE WITH DRUGS OR ALCOHOL without proper ATV training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger...

Page 5: ...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 6: ...quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are...

Page 7: ...ion 4 Safety 7 Features and Controls 28 Operation 52 Emission Control Systems 76 Maintenance 77 Troubleshooting 129 Polaris Products 133 Specifications 134 Declaration of Conformity 136 Warranty 137 M...

Page 8: ...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 9: ...driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV K...

Page 10: ...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 11: ...V RiderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforc...

Page 12: ...r on approved models should wear a hel met that includes a rigid chin guard Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and...

Page 13: ...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 14: ...nt types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the gu...

Page 15: ...ange clothing 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 in an enclosed area The engine ex...

Page 16: ...carry a passenger until you have at least two hours of driving experience with this vehicle Carrying More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to...

Page 17: ...Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public st...

Page 18: ...should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Turning Impr...

Page 19: ...manual See page 65 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Never operate in TURF mode while operating on a hill or other irr...

Page 20: ...then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 66 If the ATV begins rolling backwards Keep operator and passenger body...

Page 21: ...n Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control...

Page 22: ...stacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme cautio...

Page 23: ...brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading t...

Page 24: ...water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway appr...

Page 25: ...increased risk of overturn and loss of control Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Hot Exhaust Systems Exhaust system components are very hot...

Page 26: ...HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper ATV training or instructio...

Page 27: ...arning AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle grad...

Page 28: ...S use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests while seated in the passenger seat tell operator to slow down or stop if uncomfortable get off...

Page 29: ...oading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 735 lbs 333 kg Lug nut tor...

Page 30: ...ront Rack and Container Load 120 lbs 54 kg 7175847 Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed...

Page 31: ...ns Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maxi...

Page 32: ...override switch The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on This switch is also used to toggle through the modes of the rider information center See page 43 E...

Page 33: ...RF mode See page 38 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch to turn the lights on and off...

Page 34: ...ctronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throt...

Page 35: ...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 36: ...lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the mas...

Page 37: ...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 38: ...foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system The auxiliary foot brake is located on the inside of the right footrest Operate this brake...

Page 39: ...ne is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattende...

Page 40: ...ing a hill See page 38 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indica tor light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engag...

Page 41: ...rol and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Engaging 4X4 The 4X4 switch may be turned on or off while t...

Page 42: ...ollow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in g...

Page 43: ...pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Always refuel with the engine stopped and outdoors or in a well ventilated area Ref...

Page 44: ...e 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever is securely l...

Page 45: ...ions 6 Lower the operator backrest to create the passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base 7 Test the passenger seat lock out by attempting to...

Page 46: ...in the illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following compo nents in the front compart ment Radiator cap Brake fluid reservoir...

Page 47: ...equipped high beam status battery voltage warning temperature warning and diagnos tic display mode These features are outlined on the following pages NOTICE High water pressure may damage ATV compone...

Page 48: ...iagno sis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 47 1 Gear Indicator This indicat...

Page 49: ...wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 48 for resetting instructions 9 Und...

Page 50: ...also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the over ride button as a MODE button This feature does not contain a vehic...

Page 51: ...button until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is disp...

Page 52: ...button to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1...

Page 53: ...nactive codes are stored in the history of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the...

Page 54: ...mp etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in th...

Page 55: ...ge Too High 523 3 Signal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Ignition Coil Primary Driver 1 MAG Driver Open Grounded 1268 5 Driver Circuit Sho...

Page 56: ...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 57: ...rottle 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 54 6 Pull only light loads 7...

Page 58: ...on Tires Inspect condition and pressure 98 Wheels fasteners Inspect ensure fastener tightness 98 99 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 39 82 Coolant...

Page 59: ...and darkness Clean headlights fre quently and replace burned out headlamps promptly 7 Drive in a manner appropriate for your skills your passenger s skills and operating conditions Never operate at e...

Page 60: ...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 61: ...ey to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating...

Page 62: ...side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determin...

Page 63: ...the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of tr...

Page 64: ...ways make sure the passenger seat lock out is functioning properly before carrying a passenger 6 Lock the parking brake 7 Mount the vehicle from the left side After the operator is seated the passenge...

Page 65: ...r hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 14 Make sure the passenger understands the importance of active riding When hill...

Page 66: ...traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin...

Page 67: ...ximum 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill A pass...

Page 68: ...ow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remount...

Page 69: ...descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling...

Page 70: ...66 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m...

Page 71: ...the vehi cle or on the left if the vehicle is pointing straight uphill A passen ger should not remount until the vehicle returns to firm level ground 5 Staying uphill of the vehicle turn the handlebar...

Page 72: ...id 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 vehicle to y...

Page 73: ...onstantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never at...

Page 74: ...turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward veh...

Page 75: ...an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear whee...

Page 76: ...at cannot be centered secure the load and operate with extra caution SECURE ALL LOADS BEFORE OPERATING Unsecured loads may shift and create unstable operating conditions which could result in loss of...

Page 77: ...ys load the cargo box with the load as far forward as possible 2 Do not obstruct the headlight beam with cargo 3 Use low forward gear when hauling or towing heavy cargo to extend belt life 4 Always op...

Page 78: ...maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never...

Page 79: ...ion the weight as far forward and as low as possible 6 Pull the cargo box release lever upward 7 Lift the front of the cargo box and dump the cargo 8 Lower the cargo box and make sure the release latc...

Page 80: ...bject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases ar...

Page 81: ...vice 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 ap...

Page 82: ...tenance interval is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 54 Front s...

Page 83: ...etc Shift linkage 50 H 6 M 500 800 Inspect lubricate Q Steering 50 H 6 M 500 800 Lubricate X Front suspension 50 H 6 M 500 800 Lubricate X Rear suspension 50 H 6 M 500 800 Lubricate Q E Throttle Cable...

Page 84: ...ug 100 H 12 M 1000 1600 Inspect replace as needed X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and...

Page 85: ...Torque Inspection Procedure Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 15 17 ft lbs 20 23 Nm Page 82 Transmission Oil Synthetic Sportsman XP Transmission Fluid 32 oz 950 ml 10 14 ft l...

Page 86: ...endations capacities and plug torques Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature opera...

Page 87: ...the oil dipstick and fill tube from the left side of the ATV Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall and tighten the dipstick 4 Remove the dipstick and check the oil level 5 Add...

Page 88: ...tart the engine Allow it to warm up at idle for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the...

Page 89: ...is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 13 Remove the dipstick Add the p...

Page 90: ...drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 97 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the...

Page 91: ...and drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recom mended fl...

Page 92: ...products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do not overfill Oi...

Page 93: ...3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the rec...

Page 94: ...Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primary operation in ADC mode We recommend the use of Polaris Demand Drive Plus Fluid for the ADC u...

Page 95: ...ctive caps from the bleeder valves 6 Slowly loosen one of the screws turn counter clockwise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow R...

Page 96: ...wn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and mai...

Page 97: ...cap under the front storage com partment 1 View the fluid level in the bottle 2 If the level is low remove the front rack 3 Remove the bottle cap and add coolant as needed Maintain the coolant level b...

Page 98: ...n 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 before...

Page 99: ...r brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operat...

Page 100: ...so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 o...

Page 101: ...r upward Lift the front of the cargo box 3 Grasp edge of the seat near the left rear corner 4 Pull upward abruptly to disen gage the under seat fasteners 5 Remove the seat Side Panel Footwell Removal...

Page 102: ...m mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retenti...

Page 103: ...he vehicle to the ground 6 Torque 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 al...

Page 104: ...Remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main...

Page 105: ...rrect any short cir cuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front rack 2 Remove the fuse box cover 3 Remove the suspect fu...

Page 106: ...in leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Lift the pod cover a...

Page 107: ...r of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlig...

Page 108: ...Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to re...

Page 109: ...re the head lamp Taillight Brakelight Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Rem...

Page 110: ...n 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 107 CAUTION A hot exhaust system and engine can cause...

Page 111: ...gine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled in...

Page 112: ...o water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times using the ele...

Page 113: ...n from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever...

Page 114: ...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 115: ...ain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry th...

Page 116: ...ulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten eg...

Page 117: ...tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery Battery R...

Page 118: ...nd 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 cause an e...

Page 119: ...ning battery charge by using a Polaris Bat tery 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...

Page 120: ...e sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing st...

Page 121: ...ndard 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 122: ...2 3 mm should be visible between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far e...

Page 123: ...ase see your Polaris dealer for ser vice 7 With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommende...

Page 124: ...or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height...

Page 125: ...n adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accesso...

Page 126: ...ock the parking brake 4 Always secure the seat in the 1 up position to prevent loss during transporting 5 Secure the fuel cap and oil cap 6 Always tie the frame of the ATV to the transporting unit sec...

Page 127: ...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 128: ...washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furn...

Page 129: ...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 130: ...k 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel...

Page 131: ...llow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of c...

Page 132: ...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 preve...

Page 133: ...Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over larg...

Page 134: ...uled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low b...

Page 135: ...inked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer...

Page 136: ...oose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean...

Page 137: ...6 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun K...

Page 138: ...ot to exceed 400 lbs 181 kg Hitch Towing Rating 1500 lbs 680 kg on level ground Unbraked Trailer Towing Capacity 1995 lbs 905 kg Overall Length 93 25 in 237 cm Overall Width 47 6 in 121 cm Overall Hei...

Page 139: ...draulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt...

Page 140: ...009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH...

Page 141: ...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 142: ...parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty app...

Page 143: ...y abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatib...

Page 144: ...ur 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 addit...

Page 145: ...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 146: ...s registered 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 a...

Page 147: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 148: ...ue to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing compet...

Page 149: ...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 150: ...146 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 151: ...147 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 152: ...93 Coolant Radiator 94 Cooling System 92 94 Corrosion Removal Chrome 125 Crankcase Emission Control System 76 D Demand Drive Fluid 87 Diagnostic Codes 51 Disengaging Active Descent Control 38 Display...

Page 153: ...High Range Use 111 Hub Tightening 98 I Idle RPM Adjustment 118 Immersion Maintenance 108 Instrument Cluster 43 51 K Key Switch 29 K Turn 66 67 L Lights 102 105 Headlight Replacement 104 Headlight Lamp...

Page 154: ...ive Speeds 13 Exhaust Exposure 11 Failure to Inspect 11 S Safety Warnings Frozen Bodies of Water 20 Handling Gasoline 11 Hot Exhaust Systems 21 Improper Cargo Loading 19 Improper Hill Climbing 15 Impr...

Page 155: ...es 98 99 Wheel Installation 99 Wheel Nut Torque 99 Wheel Removal 98 Toe Alignment 96 Towing Capacities 74 Towing Loads 74 Trail Etiquette 56 Training 7 Transmission 35 Transmission Oil 86 Transporting...

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Polaris Sportsman 9922051, Owner'S Manual

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