Polaris Sportsman 9922237 Owner'S Manual Download

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135

WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or 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 HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due 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 competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. Polaris may deny warranty claims for failures that have been caused by

the owner’s or operator’s improper maintenance or use, by accidents for which Polaris

has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your vehicle. Polaris recommends that you contact an autho-

rized Polaris dealer to perform any service that may be necessary for your vehicle.

Polaris also recommends that you use only Pure Polaris parts. It is a potential violation

of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the

effectiveness of the vehicle's emission controls. Tampering with emission controls is

prohibited by federal law.
If you have any questions regarding your warranty rights and responsibilities, please

contact the Polaris Warranty Department at 1-888-704-5290.

Summary of Contents for Sportsman 9922237

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: ...VER 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 passenge...

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: ...ality 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 i...

Page 7: ...ion 4 Safety 7 Features and Controls 26 Operation 42 Emission Control Systems 66 Maintenance 67 Troubleshooting 120 Specifications 124 Polaris Products 126 Declaration of Conformity 127 Warranty 128 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: ...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 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: ...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 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: ...den 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 or...

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: ...dures for traveling down hills as described in the owner s manual See page 58 Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avo...

Page 20: ...ure described in the owner s manual See page 56 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling bac...

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: ...ls on the ATV If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge...

Page 27: ...OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and us...

Page 28: ...roved 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 and walk if...

Page 29: ...ed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Reverse Override Warning AWD C...

Page 30: ...le the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before activating the override switch The override switch also allows activati...

Page 31: ...p switch will shut off all electrical power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 47 AWD Switch Use the AWD switch to engage 4X4 or 2X4 S...

Page 32: ...c 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 throttle me...

Page 33: ...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 34: ...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 35: ...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 36: ...used as a backup for the main brake system Should the main system fail use the auxiliary foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system Th...

Page 37: ...ssion damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and whe...

Page 38: ...ar rack Press down firmly on the seat pad until the latch clicks Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to...

Page 39: ...switch allows activation of AWD in reverse if the AWD switch is on See page 26 There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off...

Page 40: ...nction that limits the ATV s speed to approximately 7 9 mph 11 14 km h Refer to page 26 for additional information NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a g...

Page 41: ...ndicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also...

Page 42: ...es traveled by the ATV 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 In the...

Page 43: ...nd on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the...

Page 44: ...your 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 pur...

Page 45: ...button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 If you scroll past the intended number press and hold...

Page 46: ...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 47: ...y the 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 44 6 Pull only light...

Page 48: ...tion Tires Inspect condition and pressure 87 Wheels fasteners Inspect ensure fastener tightness 87 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 34 72 Coolan...

Page 49: ...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 50: ...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 51: ...ome wet fouled 7 If the engine is cold pull the choke knob out until it stops Tip The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed comple...

Page 52: ...over 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...

Page 53: ...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 54: ...page 8 4 Perform the pre ride inspection See page 44 5 Always make sure the passenger seat is installed and securely latched before operating with a passenger 6 Lock the parking brake 7 Mount the veh...

Page 55: ...and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar dev...

Page 56: ...Steer in 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 balan...

Page 57: ...traction NOTICE Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin...

Page 58: ...lls with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill A passenger should also shift body weight uphill 7 Proceed at a steady rate of speed and th...

Page 59: ...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 60: ...56 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 61: ...urns to firm level ground 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 yo...

Page 62: ...hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply...

Page 63: ...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 64: ...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 65: ...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 66: ...oid 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 wheels on the dow...

Page 67: ...THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can c...

Page 68: ...he rear rack and mounted as low as possible 2 When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions 3 Do not obstruct the headlight beam with c...

Page 69: ...rear rack capacity The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the m...

Page 70: ...fr 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 exit through...

Page 71: ...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 72: ...es at whichever maintenance 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 Checklis...

Page 73: ...rication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Carburetor float bowl 50 H 6 M 500 800 Drain bowl periodically and prior to storage Shift linkage 50 H 6 M 500 800 Inspect lubricate...

Page 74: ...M 1000 1600 Inspect for leaks X Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect Q E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed X Wiring 100...

Page 75: ...se grease zerks have been provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Inspection Procedure Engine Oil Polaris Premium 4 Synthetic 0W40 2 qt 1 9 l Se...

Page 76: ...cosity and frictional breakdown in ambi ent temperatures from 40 F to 120 F 40 to 49 C Its excep tional frictional properties result in more efficient operation more power output and lower fuel consum...

Page 77: ...e If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the di...

Page 78: ...rain plug The sealing sur faces on drain plug and crank case should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 9 Disconnect the lower oil...

Page 79: ...n additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case 17 Reinstall the drain plug The seali...

Page 80: ...ely 2 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 Remove the vent line clamp If...

Page 81: ...ant See page 126 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 on the right side of the...

Page 82: ...der the gearcase 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug Torque to 20 25 ft lbs 27 34 Nm 5 Add 32 oz 948 ml of the recommended oil 6 Reinstall th...

Page 83: ...se of other fluids may result in improper operation of components See page 126 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads See below for ca...

Page 84: ...10 ft lbs 11 14 Nm Fluid Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the demand drive unit 4 Remove the drain plug Allow the fluid to drain compl...

Page 85: ...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 86: ...nt The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 86 2 Maintain the coolant level between the minimum and maximum marks on the bot tle when the fl...

Page 87: ...e 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 removing the pressure cap 1...

Page 88: ...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 89: ...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 90: ...ide panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels ali...

Page 91: ...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 92: ...the 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...

Page 93: ...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 fil ter if needed 6 Reinstall the fil...

Page 94: ...ently through the filter in the direction of the arrow to check for clog ging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reins...

Page 95: ...nt on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3...

Page 96: ...touch a lamp clean it with denatured alcohol 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressi...

Page 97: ...rn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on th...

Page 98: ...ing harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove...

Page 99: ...tall the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back...

Page 100: ...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 97 CAUTION A hot exhaust system and engine can cause b...

Page 101: ...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 102: ...er are non adjust able Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Tip Accessory spring...

Page 103: ...r 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 104: ...1800 m and temperatures below 40 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your P...

Page 105: ...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 106: ...ry the air box and replace the filter with a new filter 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 6 Turn the engine over several times using the electric st...

Page 107: ...rge accumulated carbon 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 relea...

Page 108: ...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 109: ...e to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed...

Page 110: ...ARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to i...

Page 111: ...oduce 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...

Page 112: ...sconnect the black negative battery cable first 5 Disconnect the red positive battery cable last 6 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spi...

Page 113: ...tions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cau...

Page 114: ...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 115: ...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 116: ...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 117: ...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 118: ...ler to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any wat...

Page 119: ...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 120: ...llow 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 exhaust systems...

Page 121: ...slightly rearward 2 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of Premium 4 Synthetic 0W40 engine oil into the cylinder 3 Reinstall the spark plug Torque to specification...

Page 122: ...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 123: ...ce the transmission in PARK 3 Lock the parking brake 4 Secure the fuel cap and oil cap 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach ti...

Page 124: ...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 125: ...on Fouled 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...

Page 126: ...nt 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 Electronic throttle control m...

Page 127: ...ion 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 or replac...

Page 128: ...in 218 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil...

Page 129: ...25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Sin...

Page 130: ...2872277 Premium Demand Drive Hub Fluid 9 5 l 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 2871322 Prem...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...section of your manual to your dealer each time your vehi cle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE MILES KM OR HOURS TECH...

Page 141: ...137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 142: ...ning and Storage 113 118 Clothing 9 Clutching 125 C Cold Weather Operation 48 Consumer Product Safety 7 Coolant Bottle 82 Coolant Radiator 83 Cooling System 81 83 Corrosion Removal Chrome 115 Crankcas...

Page 143: ...Hub Tightening 87 I Idle RPM Adjustment 100 Immersion Maintenance 102 Instrument Cluster 36 41 J Jetting Chart 125 K Key Switch 27 K Turn 56 57 L Lights 92 95 Headlight Housing 94 Headlight Lamp 92 Hi...

Page 144: ...to Inspect 11 S Safety Warnings 10 21 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 S...

Page 145: ...s 87 88 Wheel Installation 88 Wheel Nut Torque 88 Wheel Removal 87 Toe Alignment 85 Towing Loads 65 Trail Etiquette 46 Training 7 Transmission 33 Transmission Oil 77 78 Transporting the ATV 119 Tread...

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