Polaris Sportsman 9922172 Page 138 Owner'S Manual Download

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136

INDEX

Numerics

4X4 System . . . . . . . . . . . . . . . . . 30-31

Accessories . . . . . . . . . . . . . . . . . . 122

Active Descent Control Fluid . . . 80-81

Active Descent Control System. . . . 31

ADC System . . . . . . . . . . . . . . . . . . 31

Age Restrictions. . . . . . . . . . . . . . . . . 7

Air Filter . . . . . . . . . . . . . . . . . . . . . 96

All Wheel Drive Switch. . . . . . . . . . 22

All Wheel Drive System . . . . . . . 30-31

Battery . . . . . . . . . . . . . . . . . . 111-116

Charging (Conventional) . . . . 115

Charging (Sealed) . . . . . . 115-116

Fluid (Conventional) . . . . . . . 114

Installation . . . . . . . . . . . . . . . 113

Removal. . . . . . . . . . . . . . . . . 112

Storage . . . . . . . . . . . . . . . . . . 114

Boots . . . . . . . . . . . . . . . . . . . . . . . . 19

Brake Fluid . . . . . . . . . . . . . . . . . 84-86

Brake Inspections. . . . . . . . . . . . . . . 87

Brake, Foot . . . . . . . . . . . . . . . . . . . 25

Brake, Hand . . . . . . . . . . . . . . . . . . . 25

Brake, Parking . . . . . . . . . . . . . . . . . 26

Brakes . . . . . . . . . . . . . . . . . . . . . . . 87

Break-In Period . . . . . . . . . . . . . . . . 42

Breather Filter . . . . . . . . . . . . . . . . . 97

Breather Hose . . . . . . . . . . . . . . . . . 97

Cargo . . . . . . . . . . . . . . . . . . . . . . . . 63

Cargo Loading . . . . . . . . . . . . . . . . . 62

Chrome Wheel Care . . . . . . . . . . . 119

Cleaning and Storage. . . . . . . . 117-122

Clock, Setting Time . . . . . . . . . . . . . 35

Clothing . . . . . . . . . . . . . . . . . . . . . . 19

Clutching . . . . . . . . . . . . . . . . . . . . 125

Cold Weather Operation . . . . . . . . . 45

Coolant Bottle . . . . . . . . . . . . . . . . . 82

Coolant, Radiator. . . . . . . . . . . . . . . 83

Cooling System . . . . . . . . . . . . . . 82-83

Corrosion Removal, Chrome . . . . . 119

Demand Drive Fluid . . . . . . . . . . 78-79

Differential Switch . . . . . . . . . . . . . . 23

Disengaging Active Descent Control 31

Drive Belt Wear/Burn . . . . . . . . . . . 127

Drivetrain Break-In . . . . . . . . . . . . . . 42

Driving Downhill. . . . . . . . . . . . . . . . 53

Driving in Reverse. . . . . . . . . . . . . . . 61

Driving on a Sidehill . . . . . . . . . . . . . 52

Driving on Slippery Surfaces . . . . . . 58

Driving Over Obstacles . . . . . . . . . . . 59

Driving Procedures . . . . . . . . . . . . . . 46

Driving Through Water . . . . . . . . 56-57

Driving Uphill . . . . . . . . . . . . . . . 50-51

Driving with a Passenger. . . . . . . 48-49

Electromagnetic Interference. . . . . . . 64

Electronic Throttle Control . . . . . . . . 24

Engaging 4X4 . . . . . . . . . . . . . . . . . . 31

Engaging Active Descent Control . . . 31

Engine Break-In. . . . . . . . . . . . . . . . . 42

Engine Fogging . . . . . . . . . . . . . . . . 121

Engine Oil . . . . . . . . . . . . . . . . . . 70-75

Equipment Modifications . . . . . . . . . . 7

Exhaust Emission Control System . . 64

Eye Protection . . . . . . . . . . . . . . . . . . 19

Fluid

Active Descent Control . . . . 80-81

Brake . . . . . . . . . . . . . . . . . . 84-86

Demand Drive . . . . . . . . . . . 78-79

Engine Oil . . . . . . . . . . . . . . 70-75

Front Gearcase. . . . . . . . . . . 78-79

Transmission . . . . . . . . . . . . 76-77

Fluid Change

ADC Fluid . . . . . . . . . . . . . . . . . 81

Demand Drive . . . . . . . . . . . . . . 79

Engine Oil . . . . . . . . . . . . . . 72-75

Transmission . . . . . . . . . . . . . . . 77

Fluid Level

ADC Fluid . . . . . . . . . . . . . . . . . 80

Demand Drive . . . . . . . . . . . . . . 78

Engine Oil . . . . . . . . . . . . . . . . . 71

Transmission . . . . . . . . . . . . . . . 76

Summary of Contents for Sportsman 9922172

Page 1: ...y It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety 2009 Sportsman 500 Touring Qu...

Page 2: ...ie dieses Fahrzeug bedienen oder fahren Antes de operar o conducir este veh culo lea el Manual del propietario Lire le Manuel d utilisation avant d utiliser ou de conduire ce v hicule Prima di usare o...

Page 3: ...orcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Servic...

Page 4: ...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 intend...

Page 5: ...NTS Know Your Vehicle 5 Safety 6 Features and Controls 20 Operation 41 Emission Control Systems 64 Maintenance 65 Specifications 124 Polaris Products 126 Troubleshooting 127 Warranty 131 Maintenance L...

Page 6: ...4...

Page 7: ...rs Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key...

Page 8: ...symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The saf...

Page 9: ...ombination on public roads is prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road Equipment Modifications The warranty on your Polaris Quadricycle...

Page 10: ...laris web site at www polarisindustries com Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels and have completed a certified safety...

Page 11: ...r face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating a Quadricycle Never operate at excessive speeds Travel and turn at speeds appropriate fo...

Page 12: ...er 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 Always tra...

Page 13: ...before attempting larger hills Avoid climbing hills steeper than 15 Never operate with the differential unlocked while operating on a hill or other irregular terrain See pages 23 and 31 Always move th...

Page 14: ...ollow the procedures outlined in this manual for operating over obstacles See page 59 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution...

Page 15: ...r your vehicle Maintain the proper tire pressure Never modify a Quadricycle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be pro...

Page 16: ...ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting Always unlock the steering before starting the engine See page 28 Hot components can cause serious burns...

Page 17: ...afety decals are provided by Polaris at no charge The part number is printed on the decal The following pages repeat the information found on each decal General Alert Multi Lingual Before you operate...

Page 18: ...ND ACCESSORIES Read Owner s Manual for more detailed loading information Reverse Override Alert Pushing reverse override button may cause sudden increases in power and traction if too much throttle is...

Page 19: ...g Front and Rear WARNING WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 lbs 41...

Page 20: ...bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distin...

Page 21: ...rsonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and...

Page 22: ...ncel the reverse speed limit function NOTE The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on WARNING Activating the override switch while the throttle is open can ca...

Page 23: ...ey fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could resul...

Page 24: ...thers of an emergency or other situation requiring caution Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light The indicator on the pod will...

Page 25: ...e move the switch to the locked position This feature will function only if the vehicle is in 2X4 mode Operating with the differential unlocked when on sloped uneven or loose terrain could cause loss...

Page 26: ...leases the throttle lever The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms W...

Page 27: ...s both front and rear brakes Squeeze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure WARNING Ag...

Page 28: ...lebar 3 Push the parking brake lock forward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever WARNING Operating the Quadricycle while t...

Page 29: ...starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly 2 Pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine Extending the rec...

Page 30: ...ust be replaced if the keys are lost 4 Reverse the procedure to unlock the steering The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before...

Page 31: ...lever to the desired gear See your dealer if you experience any shifting problems Passenger Seat Always make sure the passenger seat is installed and securely latched before operating with a passenger...

Page 32: ...hen the switch is on 4X4 the vehicle is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels los...

Page 33: ...ways switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle descends a h...

Page 34: ...In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose us...

Page 35: ...ark 2 4X4 Indicator This indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Odometer Tachometer Tripme...

Page 36: ...on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Informatio...

Page 37: ...button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diag...

Page 38: ...r dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purpos...

Page 39: ...nce To reset the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button...

Page 40: ...rs flash then press and release the button once When the display stops flashing the mode has been set Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polar...

Page 41: ...es code 36 5 A code 61 will signal the end of the sequence If no blink codes are found only codes 12 and 61 will appear during the sequence NOTE The word WAIt will remain on the screen through this en...

Page 42: ...c Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Mal...

Page 43: ...ated area Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause a spark Do not smoke or allow open flames or sparks in or near the area wh...

Page 44: ...s of use Engine and Drivetrain Break in 1 Fill the fuel tank with the recommended fuel See page 28 2 Check the engine oil level See page 70 Add oil if necessary 3 Select an open area that allows room...

Page 45: ...bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 28 70 Coolant level if applicable Ensure proper level 82 83 Coolant hoses if applicable Inspect for leaks Throttle Ensure pro...

Page 46: ...hile starting the engine 5 Turn the ignition key past the POSITION LIGHTS ON position to engage the starter Activate the starter for a maxi mum of five seconds releasing the key when the engine starts...

Page 47: ...damage Any condensation must be drained Always operate the engine long enough to reach operating temperature which reduces condensation See your Polaris dealer for engine heater kits which provide qui...

Page 48: ...eep your feet on the footrests Keep both hands on the handlebars 6 Start the engine and allow it to warm up 7 Apply the brakes 8 Shift the transmission into gear 9 Check your surroundings and determin...

Page 49: ...n leaning your upper body to the inside of the turn while support ing your weight on the outer foot rest Use the same leaning technique for turning in reverse 3 Never turn quickly when carrying a pass...

Page 50: ...dricycle 1 Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles 2 Make sure the passenger is wearing appropriate riding gear inclu...

Page 51: ...ore time and distance for braking 9 Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle 10 Do not cross a hillside with a passenger on board See page 52 11...

Page 52: ...mum 3 Avoid hills with slippery or loose surfaces 4 Keep both feet on the footrests 5 Shift body weight uphill 6 Drive straight uphill 7 Proceed at a steady rate of speed to avoid stalling 8 Be alert...

Page 53: ...c parking brake 3 A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Use the K turn to turn...

Page 54: ...hillside with a passenger on board Ask the passenger to dismount and walk across the hillside 6 Shift your weight uphill 7 Keep your feet on the footrests 8 Steer slightly into the hill NOTE If the ve...

Page 55: ...low down 4 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 5 Shift your weight rearward 6 Apply the brakes slightly to aid in slowin...

Page 56: ...parking brake 4 Leave the transmission in forward gear Turn the engine off 5 A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the...

Page 57: ...d start the engine 13 Squeeze and release the brake lever to release the parking brake 14 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the ve...

Page 58: ...les 4 Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward mot...

Page 59: ...on page 104 Have the vehicle serviced by your dealer promptly Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water If the vehic...

Page 60: ...atch the trail 5 Avoid quick sharp turns 6 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 7 Never apply the brakes during a skid Always fol...

Page 61: ...rea 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches 5 Always have a passenger dismount before operating over an...

Page 62: ...RATION Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill...

Page 63: ...owly Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the throttle suddenly 6 Do not use the override switch unless additional power is required for vehicle movement...

Page 64: ...g condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Sp...

Page 65: ...g an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 17 cm Never install automo...

Page 66: ...It is required that this spark arrestor remain installed and functional when the vehicle is operated Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fue...

Page 67: ...portant for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe Use Definition Frequent immersion in mud...

Page 68: ...er comes first Remarks Hours Calendar Kilometers Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 43 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake...

Page 69: ...ct clean if needed X Engine oil change break in 1 M Perform a break in oil change at one month X General lubrication 50 3 M 800 Lubricate all fittings pivots cables etc Shift linkage 50 6 M 800 Inspec...

Page 70: ...for leaks X Engine mounts 100 12 M 1600 Inspect Exhaust muffler pipe 100 12 M 1600 Inspect Q E Spark plug 100 12 M 1600 Inspect replace as needed X Wiring 100 12 M 1600 Inspect for wear routing securi...

Page 71: ...have been provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l See page 70 Brake Fluid DOT...

Page 72: ...need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation Mixing brands or using a non recommended...

Page 73: ...ngine Allow it to idle for 30 seconds 4 Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil a...

Page 74: ...4 Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the oil tank 7 Remove the drain plug 8 Drain the oil 9 Clean the drain plug Reinstall the drain plug with a new seali...

Page 75: ...34 N m 13 Reattach the oil line 14 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 15 Clean the filter sealing area on the crankcase 16 Lubr...

Page 76: ...iters initially 22 Reinstall the dipstick 23 Place the transmission in PARK 24 Prime the oil pump using the procedure on page 75 25 Stop the engine Check for oil leaks 26 Check the oil level Add oil a...

Page 77: ...disconnected 1 Clamp the vent line 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3...

Page 78: ...ecommendations Transmission Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Check the oil level Add the recommended oil as needed Do not o...

Page 79: ...in PARK 3 Remove the fill plug 4 Remove the drain plug 5 Drain the oil into a drain pan 6 Clean the drain plug 7 Reinstall the drain plug Torque to specification See page 76 8 Add the recommended oil...

Page 80: ...fluid level at the bottom of the fill hole threads Fluid Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Add the recommended demand drive flu...

Page 81: ...e transmission in PARK 3 Remove the fill plug 4 Remove the drain plug Drain the fluid into a drain pan 5 Clean the drain plug 6 Reinstall the drain plug Torque to specification See page 78 7 Add the r...

Page 82: ...umbers of Polaris products Fluid Level 1 Position the vehicle on a level surface 2 Open the front box cover 3 Open the access door 4 View the fluid level in the reservoir 5 Remove the cap and add the...

Page 83: ...luid 5 Remove the protective caps from the bleeder valves 6 Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean f...

Page 84: ...126 for the part num bers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level dr...

Page 85: ...dd coolant through the radiator filler neck 5 Reinstall the pressure cap 6 Secure the access door and box cover NOTE Use of a non standard pressure cap will not allow the recovery system to function p...

Page 86: ...ak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING Operating t...

Page 87: ...erfill 1 Position the vehicle on a level surface Make sure the handlebars are straight 2 View the fluid level through the indicator win dow eye on the top of the master cylinder NOTE The eye will appe...

Page 88: ...icle on a level surface 2 Open the front box cover 3 Open the access door 4 View the fluid level in the reservoir 5 Remove the cap and add the recommended fluid as needed NOTE DO NOT use ADC fluid 6 M...

Page 89: ...ake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 84 2 Check the brake systems regular...

Page 90: ...NOTE 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 of the front rim The rear measurement should be 2 3 mm...

Page 91: ...of the machine when turned fully to the left or right 4 Torque the front two bolts to 14 17 N m then torque the rear two bolts A gap of up to 3 mm will remain at the rear of the clamp blocks WARNING I...

Page 92: ...for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Rear Spring The rear shock absorber spring is adjusted by rotating the adjus...

Page 93: ...panel from the grommet 4 Pull the panel downward and rearward to remove it 5 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the six screws...

Page 94: ...n the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay is achieved at the thumb lever NOTE Move the throttle lever back and forth while adjusting 5 Tighten the loc...

Page 95: ...ce must be performed by your authorized Polaris dealer WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle han...

Page 96: ...Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 122 Nm 2 Piece Flange Nut 37 Nm Cast Alumin...

Page 97: ...ce 2 Place the transmission in PARK 3 Loosen the wheel nuts slightly 4 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 5 Remove the wheel nuts 6 Remove the w...

Page 98: ...icle on a level surface 2 Place the transmission in PARK 3 Remove the seat 4 Release the air box cover clips 5 Remove the air box cover 6 Loosen the hose clamp 7 Remove the filter 8 Remove the pre fil...

Page 99: ...ect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or...

Page 100: ...from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 4 Start the engine Turn the head light switch to high...

Page 101: ...osition light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully rem...

Page 102: ...everse order Front Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Remove the lens attachment screw 3 Rotate the lamp to remove it 4 Install the new lamp 5 Reinstall the lens Rear Turn...

Page 103: ...fuse may need replacement NOTE Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover 2 Open the access door 3 Remove the suspect fuse from the fuse panel...

Page 104: ...There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white ins...

Page 105: ...spark plug wrench to remove the spark plug Turn the plug counterclockwise to remove it 4 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at spec...

Page 106: ...ore further operation perform the following pro cedure If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dea...

Page 107: ...the spark plug Reinstall the plug or install a new plug 6 Torque to specification See page 102 7 Attempt to start the engine If necessary repeat the drying procedure 8 Have the vehicle serviced by you...

Page 108: ...the engine 5 Quickly squeeze and release the throttle lever several times to purge car bon from the system WARNING Allow components to cool sufficiently before servicing The exhaust system can get ex...

Page 109: ...et while repeat ing step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels 9 Place the transmission in PARK Repeat...

Page 110: ...at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the followin...

Page 111: ...to drain completely Rein stall the drain plug 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide o...

Page 112: ...etely dry before reinstalling the drain plug 1 Place the transmission in PARK 2 Stop the engine 3 Remove the drain screw on the bottom of the recoil housing 4 Allow the housing to drain com pletely 5...

Page 113: ...hop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It...

Page 114: ...y out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTE If electrolyte spills immediately wash it off with a solution of one table spoon baking s...

Page 115: ...al batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Install the battery c...

Page 116: ...y using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically ch...

Page 117: ...front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the i...

Page 118: ...ondition before and 1 2 hours after the end of charging WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery beco...

Page 119: ...lastic surfaces Do not allow these types of products to contact the vehicle 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water freq...

Page 120: ...ntact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust...

Page 121: ...nt 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 periodi...

Page 122: ...the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys te...

Page 123: ...he Engine 1 Treat the fuel system with Polaris Carbon Clean See page 120 2 Remove the spark plug Pour 30 45 ml of engine oil into the plug holes 3 Reinstall the spark plug Torque to specification 4 Ap...

Page 124: ...tly off the ground 2 Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent...

Page 125: ...prevent loss during transporting 5 Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Towin...

Page 126: ...d Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 5 4 gal 20 5 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 7 qts 2 5 l Demand Drive Fluid Capacity 9 3 oz 275...

Page 127: ...ires Pressure Rear 25x11 12 5 psi 34 5 KPa Brake Hand All wheel hydraulic disc Brake Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all wheel Headlight 2 Hi Lo b...

Page 128: ...d 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 l Coolant 2871323 60 40 Coolant 3 8 l 2871534 60 40 Coolant 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Pre...

Page 129: ...Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range Carefully use fast aggressive throttle application to engage clutch WARNING Excessiv...

Page 130: ...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 battery voltage Re...

Page 131: ...ttery to 12 8 VDC Kinked 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 malfuncti...

Page 132: ...t gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Clogged air filter Inspect and clean or replace Reverse...

Page 133: ...pleted by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAI...

Page 134: ...ble with the Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES...

Page 135: ...ONSIBILITY Polaris suggests that you use 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...

Page 136: ...ection 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 KILOMETERS OR HOURS TEC...

Page 137: ...135 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 138: ...82 83 Corrosion Removal Chrome 119 D Demand Drive Fluid 78 79 Differential Switch 23 Disengaging Active Descent Control 31 Drive Belt Wear Burn 127 Drivetrain Break In 42 Driving Downhill 53 Driving...

Page 139: ...m Adjustment 98 Position Light Lamp 99 Rear Turn Signal 100 Taillight 100 Low Range Use 45 Lubrication Guide 69 M Maintenance Chart 65 68 Mirrors 24 Mode Switch 20 Modifications 7 N Noise Emission Con...

Page 140: ...es 20 23 4X4 Switch 22 Differential Switch 23 Engine Stop Switch 21 Hazard Warning 22 Horn 22 Light Switch 21 Main Key Switch 21 Mode Reverse Override Switch 20 Turn Signal 22 T Taillight 100 Throttle...

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Polaris Sportsman 9922172, Owner'S Manual

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