Polaris Sportsman 9922475 Owner'S Manual Download Page 136

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133

Maintenance

Brake Lever Travel

Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart

beginning on page 98. When freeplay specifications can no longer be obtained through

adjustment as outlined on the preceding pages, use the following information to determine

when to service the brakes.
Service the brakes when brake

lever travel reaches the total lever

travel measurement listed in the

table below. Always service the

brakes when there is no longer

sufficient stopping ability at the

specified lever travel setting.

Component

Total Lever Travel

Front brake lever

1 3/4" (45 mm)

Rear brake lever

2 1/2" (65 mm)

Measure

Lever

Travel

Summary of Contents for Sportsman 9922475

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: ...e conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS S use proper riding techn...

Page 4: ...1 Visit us at www polarisindustries com...

Page 5: ...and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication a...

Page 6: ...d in this owner s manual Help them also learn to show respect for our environment and for the rights of others while operating the ATV Never allow a child under the age of 16 to operate an ATV without...

Page 7: ...ed to read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay clo...

Page 8: ...Ride Check 47 Riding Rules 50 Adult Section 55 Vehicle ID Numbers 56 Features and Controls 57 Operation 69 Emission Control Systems 96 Maintenance 98 Specifications 162 Polaris Products 166 Troublesho...

Page 9: ...tial personal 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...

Page 10: ...this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Ta...

Page 11: ...RiderCoursesm that is available to you and your eligible family members This training is included in the purchase price of your ATV In addition you were provided with printed material and a video or D...

Page 12: ...2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for informa tion about safety training FOR MORE I...

Page 13: ...or exceeds 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 Th...

Page 14: ...al 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 prot...

Page 15: ...rposes Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equip...

Page 16: ...are provided for your child s safety Be sure to explain to your young driver that the hazards outlined in this section of the owner s manual MUST be avoided at all times See the RIDING RULES section...

Page 17: ...uations and on different types of terrain Beginning and inexperienced operators should complete an ATV training course They should then regularly practice the skills learned in the course and the oper...

Page 18: ...soline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off...

Page 19: ...ntenance procedures and schedules described in the owner s manual Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of a...

Page 20: ...and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect op...

Page 21: ...void 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 stre...

Page 22: ...ditions and your experience Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of...

Page 23: ...for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stu...

Page 24: ...n Always follow proper procedures for climbing hills as described in the owner s manual See page 84 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate...

Page 25: ...scribed in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 87 Always check the terrain carefully before descending a hill Shift your weight rearw...

Page 26: ...urn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 86 Never attempt t...

Page 27: ...radually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If the ATV begins rolling downhill Keep weight uphill Never apply engine power Never app...

Page 28: ...y rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the...

Page 29: ...tenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always main...

Page 30: ...ording to approved instructions See your authorized Polaris ATV dealer for more information Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before...

Page 31: ...If it s unavoidable to enter water that exceeds the height of the footrests Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sud...

Page 32: ...ndling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes...

Page 33: ...Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes thr...

Page 34: ...system Use caution when traveling through tall grass especially dry grass Always inspect the underside of the ATV after driving through tall grass weeds brush and other tall ground cover Promptly remo...

Page 35: ...the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at...

Page 36: ...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 passengers affect balance and steering and incr...

Page 37: ...ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering be...

Page 38: ...death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa Maximum Weight Capacity 180 lbs 81 7 kg 7175503 Tire Pressure Warning SPORTSMAN 90 WARNING Improper tire pressure or overloading c...

Page 39: ...36 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378...

Page 40: ...ty Safety Labels and Locations SPORTSMAN 90 Rack Warning WARNING DO NOT TOW Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 lbs 7 kg Rear 30 lbs 14 kg 7...

Page 41: ...der belt clutch guard To pre vent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause part failure...

Page 42: ...39 Youth Section...

Page 43: ...ifications section beginning on page 162 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know Your safety and the safety of other...

Page 44: ...to shut the engine off quickly The button must be up before you can start the engine again 2 Horn Button Press the horn button to sound the horn 3 Throttle Control Press the throttle lever with your t...

Page 45: ...own on the kick start lever with your foot to start the engine Have an adult show you how it works Read more about how to use the kick start on page 68 5 Shift Lever The shift lever is on the right si...

Page 46: ...have an adult put gas in your ATV Never try to do it yourself 7 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the...

Page 47: ...s the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and b...

Page 48: ...hed snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never ride without the tether stra...

Page 49: ...46 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off...

Page 50: ...t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close t...

Page 51: ...e your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you...

Page 52: ...heck the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks n This last check is done with the engine running You must check to make sure that all...

Page 53: ...riving an ATV Adults have riding rules too The rules help keep us safe when we ride X The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always d...

Page 54: ...s to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from...

Page 55: ...he ATV harder to drive You may lose control and hurt yourself and your passenger X Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests X Alwa...

Page 56: ...ght Your ATV doesn t have lights that are safe for driving in the dark X Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them X Never ride on frozen water You...

Page 57: ...54 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new Polaris ATV...

Page 58: ...55 Adult Section...

Page 59: ...with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame VIN ___________...

Page 60: ...key clockwise to the ON position before starting the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running Always remove the ignition key when th...

Page 61: ...her emergency Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Use the choke to star...

Page 62: ...htly above the choke lever 1 Attach the tether strap securely to the vehicle and to the rider s right wrist 2 Shift the transmission to neutral The neutral light will come on when the lever is in neu...

Page 63: ...te an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can re...

Page 64: ...n position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease WARNING The Electronic Throttle Control ETC stops the engine in the event of a thr...

Page 65: ...ng Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Shift Pattern F Forward Gear N Neutral R Reverse NOT...

Page 66: ...the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious i...

Page 67: ...eze and release the brake lever The parking brake will release automatically 5 Always lock the parking brake whenever the vehicle is left unattended WARNING Operating the ATV while the parking brake i...

Page 68: ...his ATV after dark Use caution and drive at reduced speeds in conditions of reduced visibility This ATV is designed for off road use only Do not operate this ATV on streets or highways Indicator Light...

Page 69: ...ted directly below the handlebars Use unleaded gasoline with a minimum 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 Refer to the...

Page 70: ...sporting ON For normal operation RES For reserve supply if main supply is exhausted The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill the gas tank as soon as pos...

Page 71: ...the left side of the ATV Tip A 10 12mm wrench is provided in the tool kit for removing or installing the lever If not installed make sure the rubber cap is on the kick start shaft to protect the ride...

Page 72: ...gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for...

Page 73: ...ling gasoline See page 15 2 Check the oil level Add the recommended oil as needed Maintain the oil level in the proper range See page 109 3 Drive slowly at first Select an open area that allows room t...

Page 74: ...st See page 72 6 Perform the following maintenance at the end of the break in period Item End of Break In Remarks See Page Engine oil change Perform break in oil change 110 Oil pre filter screen Clean...

Page 75: ...Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 129 133 Front suspension Inspect lubricate if necessary 106 Rear suspension Inspect lubricate if necessary 106 Steer...

Page 76: ...Check for proper operation 149 Brakelight Check for proper operation 147 Air filter pre filter Inspect clean or replace 140 Drive chain Check condition and slack refer to drive chain adjustment 137 F...

Page 77: ...run in an enclosed area 5 Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 6 Never exceed the maximum we...

Page 78: ...re or while operating an ATV 9 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 Never operate a damaged ATV After any overturn or accident have...

Page 79: ...the tether strap to the ATV and to your wrist 5 If the engine is cold use full choke by pushing the choke lever all the way to the left A warm engine will not require the use of the choke Tip The cho...

Page 80: ...the starter for a maximum of five seconds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the...

Page 81: ...oving 3 Shift the transmission to neutral 4 Stop the engine There are three ways to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV 5 Lock the parki...

Page 82: ...ngine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Squeeze the left brake lever 6 Shift the transmission to the desired gear 7 Slowly release the brake lever 8...

Page 83: ...side tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alt...

Page 84: ...ecautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at s...

Page 85: ...rfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slo...

Page 86: ...alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shift...

Page 87: ...mproper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 15 maximum 3 Always check the terrain carefull...

Page 88: ...tle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on...

Page 89: ...the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keepin...

Page 90: ...eep hills 15 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when trav eling downhill can cause loss of control...

Page 91: ...phill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 5 Staying uphill of the ATV turn...

Page 92: ...ATV from the uphill side keeping body weight uphill 8 Restart the engine 9 Squeeze the rear brake lever 10 Shift the transmission to forward gear 11 Release the parking brake and drive slowly controll...

Page 93: ...void parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Stop the engine 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown in t...

Page 94: ...ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfami...

Page 95: ...th for your ATV is below the bottom of the footrests Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 If crossing a stream choose a cro...

Page 96: ...he inspections and maintenance services outlined in the periodic maintenance chart beginning on page 98 Engine oil gearcase oil front and rear gearcases if equipped and all grease fittings need specia...

Page 97: ...g the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control which can result in serious injury or death Always follow these precautions when hauling cargo Place...

Page 98: ...r rope to secure the cargo Do not allow cargo or tie straps to hang over the edges of the racks Carry only small loads that fit on the racks Tall loads raise the center of gravity of the vehicle and m...

Page 99: ...with the USFS standard 5100 1c Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in...

Page 100: ...ator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or engine case near the clutch box The installation of devices...

Page 101: ...ment under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe...

Page 102: ...parts available from your Polaris dealer Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe...

Page 103: ...an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often under severe use such as in dirty or wet condi tions to purge water or dirt contaminatio...

Page 104: ...re Ride Check list 72 X Front suspension Daily X Rear suspension Daily Tires Daily X Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily X Engine oil level Daily X...

Page 105: ...t and lubricate if needed 137 CVT housing if equipped Weekly Drain water as needed check often if operating in wet conditions 121 Break in Maintenance After first 10 hours of operation Perform break i...

Page 106: ...filter screen 40 12 M 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours 111 X General lubrication 50 3 M 500 800 Lubricate all fittings pivots cables etc QE...

Page 107: ...r air intake ducts flange 50 6 M 500 800 Check for proper sealing air leaks Q Drive belt 50 6 M 500 800 See your Polaris dealer XQ Brake pad wear 50 6 M 500 800 See your Polaris dealer QE Fuel system...

Page 108: ...ect for wear routing security apply dielectric grease to connec tors subjected to water mud etc Q Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 1...

Page 109: ...c Youth Oil or Synthetic SAE 40 See page 108 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 114 Drive Chain Polaris Chain Lube or SAE 80 90 See page 137 X Front Suspensio...

Page 110: ...107 Maintenance Lubrication Guide Grease Points Grease Points...

Page 111: ...not use automotive oil See page 166 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never s...

Page 112: ...an cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moistu...

Page 113: ...sition the vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause burns to skin...

Page 114: ...pletely 7 Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry 8 Clean the pre filter plug Install a new sealing washer on the plug The sealing surfaces on the plug...

Page 115: ...mmended oil Do not overfill See the specifications section beginning on page 162 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the engine...

Page 116: ...The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98 Do not attemp...

Page 117: ...change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 166 for the part numbers of Pola...

Page 118: ...e the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fill plug hole t...

Page 119: ...ways use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle h...

Page 120: ...r throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are n...

Page 121: ...result in serious engine damage Trans port the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures out...

Page 122: ...ace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service...

Page 123: ...and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety...

Page 124: ...on to neutral 3 Start the engine 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 4 Allow th...

Page 125: ...t beginning on page 98 Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool suffi cientl...

Page 126: ...synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage R...

Page 127: ...foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from you...

Page 128: ...rbure tor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw either in or out until the desired idl...

Page 129: ...either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable throttle limiting screw Speed limiting devices may be ad...

Page 130: ...ottle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten th...

Page 131: ...le for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay fa...

Page 132: ...the intervals rec ommended in the Periodic Maintenance Chart beginning on page 98 If the free play isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specific...

Page 133: ...e front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground 4 While rotating the left front wheel tighten the upper front brake adjuster nut on...

Page 134: ...ront brake adjuster nut on the right hand control 7 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 8 Verify that the right hand brake functions correctly...

Page 135: ...rear tires should be slightly off the ground 4 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 5 When you begin to feel a slight drag in wheel rota tion loosen t...

Page 136: ...on the preceding pages use the following information to determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table b...

Page 137: ...Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ah...

Page 138: ...t rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measure ment on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement...

Page 139: ...ave your dealer tighten them before operating the ATV Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The front and rear shock absorber springs are adjustable to inc...

Page 140: ...ty or wet conditions See page 166 for the part numbers of Polaris products NOTICE Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t...

Page 141: ...he strap around the axle and rear bumper tube 3 Tighten the strap until a straight line can be drawn from the rear axle to the gearcase output shaft intersecting the swing arm pivot This establishes t...

Page 142: ...lock nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft lbs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid b...

Page 143: ...ing clips and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply a commercially av...

Page 144: ...or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat NOTICE Never operate the ATV with the filter element removed Dirt will enter the engine caus...

Page 145: ...e adjustment procedures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the pod to access the handlebar bolts Loosen the four bolts 2 Adjust...

Page 146: ...or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and...

Page 147: ...worn to 1 8 3 mm or less Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest...

Page 148: ...n the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Install the wheel bolts and finger tighten them 4 L...

Page 149: ...h a cotter pin installed must be service by an authorized Polaris dealer Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must...

Page 150: ...doesn t work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the lamp and replace it with a new recommended lamp 3 Test the light for p...

Page 151: ...er or pod to access the lamps 2 Remove the indicator wire connections from the harness 3 Remove the nut from the back side of the indicator lamp 4 Remove the lamp 5 Apply dielectric grease to the sock...

Page 152: ...he light assembly 4 Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out 5 Install the new lamp Mak...

Page 153: ...lack cable last The battery in your Polaris ATV is a sealed battery The sealing strip cannot be removed Never add water to this type of battery Keep the battery terminals and connections free of corro...

Page 154: ...y Removal 1 Disconnect the hold down straps securing the electrical box and battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 L...

Page 155: ...can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 1 Set the battery in its holder 2 Connect and tighten...

Page 156: ...g storage and recharge as needed to maintain a full charge Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components NOTICE High water...

Page 157: ...lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power w...

Page 158: ...ls Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals If warning and safety labels are damaged contact your...

Page 159: ...sh on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths an...

Page 160: ...he vehicle as recommended See page 153 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each mon...

Page 161: ...e period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount Carbon clean will also reduce th...

Page 162: ...er Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Mainten...

Page 163: ...e sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilate...

Page 164: ...s tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting 3 Wrap the front tie...

Page 165: ...e 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gallons 6 4 liters Fuel Reserve Capacity 23 gallons 86 liters Starting Electric with kick start backup Drive System Automati...

Page 166: ...Tires 19 x 7 8 3 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa Dry Weight 270 lbs 122 4 kg Length Width Height 61 25 156 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm...

Page 167: ...type 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 2 gallons 7 7 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automat...

Page 168: ...Parking Brake Mechanical Lock Front Tires 19 x 7 8 3 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa Dry Weight 289 lbs 131 kg Length Width Height 61 75 157 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5...

Page 169: ...th Oil qt 95 l 2876249 Synthetic Youth Oil gal 3 8 l 2872175 Semi Synthetic 20W 40 Oil qt 95 l 2872176 Semi Synthetic 20W 40 Oil gal 3 8 l 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants...

Page 170: ...167 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease 3 oz 89 ml 2871423 All Season Premium Grease 14 oz 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus...

Page 171: ...system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spa...

Page 172: ...charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octane fuel Replace with r...

Page 173: ...ugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect...

Page 174: ...e Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with 5 amp charger Kin...

Page 175: ...el clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of...

Page 176: ...plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conne...

Page 177: ...below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive...

Page 178: ...008 2009 2010 76 8 ___BA32__ TRAIL BLAZER 330 2008 2009 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 ___G...

Page 179: ...SPORTSMAN 850 EFI 2009 2010 80 4 ___RH50__ ___HH50__ RANGER 500 EFI 4X4 2009 2010 76 5 ___HH76__ RANGER 800 EFI 4X4 2010 76 5 ___WH76__ RANGER 800 EFI CREW 2010 76 5 ___HR__ RANGER 800 6X6 2010 76 5 _...

Page 180: ...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 181: ...ized parts In addition this war ranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery mate rial corrosion or defects in parts components or the ATV...

Page 182: ...d part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil greas...

Page 183: ...as been damaged by 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...

Page 184: ...OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Som...

Page 185: ...ey will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void...

Page 186: ...s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorize...

Page 187: ...f Purchased From A Private Party If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage...

Page 188: ...ons The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and con tinues for a period of 250 hours of engine operation 2500 kilometers 1550 miles o...

Page 189: ...s As related to the evaporative emission control system Air induction system Ignition system Fuel system Exhaust gas recirculation systems Aftertreatment devices Sensors Crankcase ventilation valves E...

Page 190: ...ENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUD...

Page 191: ...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...

Page 192: ...to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED...

Page 193: ...190 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours...

Page 194: ...191 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 195: ...192 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 196: ...ion 120 Consumer Product Safety 9 CVT Drying 121 CVT System 120 Cylinder Head Torque 118 D Daytime Running Lights 149 Drive Chain 137 Drive Chain Slack 138 Drive Chain Slack Adjustment 139 Driving Dow...

Page 197: ...de 106 107 M Main Key Switch 57 Maintenance Chart 98 105 Making Turns 80 Modifications 12 O Oil 108 Oil Change Engine 110 112 Oil Change Transmission 115 Oil Check Engine 109 Oil Check Transmission 11...

Page 198: ...p Hills 21 Operating Over Obstacles 27 Operating in Deep Water 28 Operating Without Instruction 14 Physical Control of the ATV 19 Physical Skills 30 Protective Apparel 16 Skidding or Sliding 27 Slippe...

Page 199: ...Throttle Control 41 Throttle Lever 61 Throttle Stop Speed Control 127 Tire Tread Depth 144 Tires 143 Toe Alignment 134 135 Transmission Oil 114 115 Transporting the ATV 161 Turning Around on a Hill 8...

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Polaris Sportsman 9922475, Owner'S Manual

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