Polaris Sportsman 9921837 Owner'S Manual Download

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Summary of Contents for Sportsman 9921837

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Page 3: ...y motorcycles 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 Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Please see your dealer for all of your service needs during and after the warranty period For mor...

Page 4: ...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 intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expre...

Page 5: ...NTENTS Introduction 4 Safety 7 Features and Controls 20 Operation 40 Emission Control Systems 60 Maintenance 61 Specifications 116 Polaris Products 118 Troubleshooting 119 Warranty 123 Maintenance Log 126 Index 128 ...

Page 6: ...al 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 result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 7: ... Understand all safety warnings precautions and operating procedures before operating a Polaris Tractor Never operate this vehicle without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This vehicle is approved for OFF ROAD TOWING ONLY Operating a Tractor trailer combination on public roads is prohibited See ...

Page 8: ...k 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 ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number _____________________________________________...

Page 9: ...s and the protection of our environment Read and understand your owner s manual which includes valuable informa tion about all aspects of your vehicle including safe operating proce dures Ride responsibly Know all laws and regulations concerning the opera tion of this vehicle in your area Equipment Modifications The warranty on your Polaris Tractor may be terminated if any equip ment has been adde...

Page 10: ... 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 distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Helmet Eye Protection Gloves Boots Long Pants Long Sleeves E4 05103...

Page 11: ...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 protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jer...

Page 12: ...ified safety training course Never allow anyone under 16 years of age to operate this vehicle Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in a well ventilated area Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause...

Page 13: ...ts properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating a Tractor Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience ...

Page 14: ...eet on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution Always follow the procedures outlined in this manual for turning See page 45 Never turn sharply at excessive speeds which can lead to vehicle overturn If a Tractor has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not ...

Page 15: ...switch to ADC 4X4 before ascending or descending a hill Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 49 Always follow the procedures outlined in this manual for crossing the side of a hill See page 48 Never attempt to turn the Tractor around on any hill until you ve mastered on level ground the turning technique outlined in this manual...

Page 16: ...follow the procedures outlined in this manual for operating over obstacles See page 55 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 54 Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 52 ...

Page 17: ... for your vehicle Maintain the proper tire pressure Never modify a Tractor through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking ...

Page 18: ...e 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 26 Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about Tractor safety contact an authorized Polaris Tractor dea...

Page 19: ...e provided by Polaris at no charge The part number is printed on the label The following pages repeat the information found on each label General Alert Multi Lingual Before you operate this vehicle read the owner s manual 7173025 Hill Operation Hitch Alert Never operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flip over on hilly terrain when going up or down use throttle and bra...

Page 20: ...D Switch WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in 4X4 AWD See Owner s Manual 4X4 AWD SWITCH Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual 7175106 Reverse Overri...

Page 21: ...se a loss of control resulting in SEVERE INJURY or DEATH 7175378 Clutch Cover Alert NO STEP 7173030 Rack 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 Max Rack Loads Front 90 lbs 41 kg Rear 180 lbs 82 kg 7172572 ...

Page 22: ...r while operating in reverse press the override switch before opening the throttle This will cancel the reverse speed limit function The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on Activating the override switch while the throttle is open can cause loss of control Do not activate the override switch while the throttle is open Horn Switch Hazard Switch Main Key ...

Page 23: ...ghts are on in this position Do not attach a large key 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 result in serious injury or death Engine Stop Switch The engine will not start or run when the switch is in the OFF position OFF STOP RUN Light Switch Hi...

Page 24: ... to alert others 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 also flash Return the toggle to the center position and push it inward to end the signal Horn Switch Press the horn switch to sound the horn 4X4 Switch Turn Indicators Hazard Warning Switch...

Page 25: ...te a Tractor with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement Electronic Throttle Control ETC ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases th...

Page 26: ...l brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates 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 Parking Brake 1 Place the transmission in PARK 2 Squeeze the brake leve...

Page 27: ...ngage the seat tabs from the rear seat base slots Remove the seat Make sure the seat is securely installed before operating Seat Height Adjustment To raise or lower the seat remove the seat and reposition the seat tabs in one of the rear seat base slots Make sure the seat is securely installed before operating Backrest Adjustment Loosen the backrest knobs on each side of the backrest mount and sli...

Page 28: ...ock the steering Hitches See page 116 for hitch weight capacities Front Hitch Use the front hitch for vehicle recovery or towing only Do not use the front hitch for any other purpose Always remove the front hitch before operating in forward gear Rear Hitch Hitch specifications may differ from vehicle capacity specifications Do not exceed the hitch and towing capacities specified for this vehicle S...

Page 29: ...The transmission gear selector is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttl...

Page 30: ...4 When 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 lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 The override switch allows a...

Page 31: ...y remain in 4X4 If the switch is turned off while the demand drive unit is engaged it will not disengage until the rear wheels regain traction Engage 4X4 before getting into situations where maximum traction is needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and ge...

Page 32: ...of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 po...

Page 33: ...its the vehicle s speed to approximately 11 14 km h Refer to page 20 for additional information NOTICE High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow i...

Page 34: ...rk 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 Tripmeter Hour Meter Clock 6 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will d...

Page 35: ...n 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 Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The ...

Page 36: ...on 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 diagnostic mode 2 Toggle to the clock screen 3 Press and hold the mode button until the hour display flashes Release the 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 quickl...

Page 37: ... 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 purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5...

Page 38: ...ference 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 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 If you scroll past the intended number press and hold the bu...

Page 39: ...ers 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 Polaris dealer for all major repairs See page 39 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in...

Page 40: ... times 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 The word WAIt will remain on the screen through this entire process Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to grou...

Page 41: ...ic Pressure Manifold Air Pressure Sensor Low 46 Barometric 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 Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cy...

Page 42: ...rain Break in 1 Fill the fuel tank with the recommended fuel See page 27 2 Check the engine oil level See page 66 Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary 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...

Page 43: ...nd oil Ensure proper levels 27 66 Coolant level if applicable Ensure proper level 78 79 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 23 87 Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 21 Mirrors Adjust for best side rear vision 23 Air filter pre filter Inspect clean 90 Air box sediment tube Drain deposits whenever visibl...

Page 44: ...n in PARK or neutral 3 Sit on the vehicle 4 Apply the brakes 5 Move the engine stop switch to RUN 6 Do not press the throttle while starting the engine 7 Turn the ignition key past the PARKING LIGHTS ON position to engage the starter Activate the starter for a maxi mum of five seconds releasing the key when the engine starts 8 If the engine does not start release the starter and wait five seconds ...

Page 45: ... 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 quicker warm ups and easier starting in cold weather PVT Operation When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 11 km h Low Towing heavy loads Low Operating ...

Page 46: ... both hands on the handlebars 4 Start the engine and allow it to warm up 5 Apply the brakes 6 Shift the transmission into gear 7 Check your surroundings and determine your path of travel 8 Release the brakes 9 Slowly squeeze the throttle lever toward the handlebar to begin driving 10 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 47: ... the turn leaning your upper body to the inside of the turn while sup porting your weight on the outer footrest Use the same leaning tech nique for turning in reverse 3 Never turn quickly when carrying cargo 4 Practice making turns at slow speeds before attempting to turn at faster speeds Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which ...

Page 48: ...imum 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 Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 25 Maximum ...

Page 49: ...When fully stopped lock the hydraulic parking brake 3 Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Use the K turn to turn around See page 50 Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for braking if you stall or roll backwards while c...

Page 50: ...g the sides of steep hills 4 Shift your weight uphill 5 Keep your feet on the footrests 6 If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the Tractor around on any hill until you ve mastered on level ground the turning ...

Page 51: ...maximum 3 Avoid hills with slippery or loose surfaces 4 Never drive downhill at high speed Slow down 5 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 6 Shift your weight rearward 7 Apply the brakes slightly to aid in slowing Always follow the procedures outlined in this manual for driving downhill and for braking on hills ...

Page 52: ...ll See page 30 3 Lock the hydraulic parking brake 4 Leave the transmission in forward gear Turn the engine off 5 Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 6 Stay uphill of the vehicle and turn the handlebars full left 7 Squeeze the brake lever to release the parking brake 8 Slowly release the brake lever and allow the vehicle to roll around to your r...

Page 53: ...lease 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 vehicle is on level ground Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for braking if you stall or roll backwards while ...

Page 54: ...cles 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 motion Do not make sudden turns stops or throttle changes 5 Wet brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking ...

Page 55: ... on page 98 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 vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine ...

Page 56: ... precautions 1 Slow down before driving onto slippery surfaces 2 Engage 4X4 before wheels begin to lose traction 3 Be alert Watch the trail 4 Avoid quick sharp turns 5 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 6 Never apply the brakes during a skid NOTICE Severe damage to drive train may occur if 4X4 is engaged while the wheels are ...

Page 57: ...he terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side ...

Page 58: ... 3 Drive slowly 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 Use with caution NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage ...

Page 59: ...aises the center of gravity of the vehicle and creates a less stable operating 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 Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities S...

Page 60: ...ified to tow a trailer on road Do not tow any trailer on a grade steeper than 15 Use the front hitch for vehicle recovery or towing only Always remove the front hitch before operating in forward gear The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capa...

Page 61: ...ongue weight capacity can result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 10 cm Never install auto motive accessories on your Polaris Tractor Always install Polaris approved or equivalent accessories designed for Tractor use Maximum 10 cm ...

Page 62: ...ired 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 fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable Electromagnetic Interference This spark ignition system complie...

Page 63: ...ortant 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 water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level duri...

Page 64: ...mes first Remarks Hours Calendar Kilometers Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 41 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever Pre Ride Foot brake Pre Ride Brake system Pre Ride Passenger seat lock out Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air ...

Page 65: ... 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 Inspect lubricate adjust Q Steering 50 6 M 800 Lubricate X Front suspension 50 6 M 800 Lubricate X Rear suspension 50 6 M 800 Lubricate Q E Throttle cable ETC switch 50 6 M 800 Inspect adjust lubricate replace if necessary E Throttle body intake duct 50 6...

Page 66: ... 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 security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 12 M 1600 Inspect clean replace worn parts Q Front wheel bearings 100 12 M 1600 Inspect replace as ...

Page 67: ...ave 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 66 Brake Fluid DOT 4 Only See page 80 Transmission Oil Polaris AGL Synthetic Gearcase Lube 32 oz 948 ml See page 72 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid 9 3 oz 275 ml See page 74 ADC Fluid Pol...

Page 68: ...d 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 NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance Synthetic 2W 50 4...

Page 69: ...engine 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 as needed Maintain the oil level in the safe range Do not overfill 8 Reinstall the dipstick Dipstick Safe Add Oil Safe Range ...

Page 70: ...onds 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 Hot oil may result in serious burns Do not allow hot oil to contact skin 9 Clean the drain plug Reinstall the drain plug with a new sealing washer 10 Torque to specification See page 66 Drain Plug New Sealing Washer Screen Fitting ...

Page 71: ...is 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 Lubricate the filter o ring Check to make sure the o ring is in good condition 17 Install the new oil filter After the filter contacts the crankcase surface turn it 1 2 turn by hand 18 Approximately one...

Page 72: ...iters initially 22 Reinstall the dipstick 23 Place the transmission in PARK 24 Prime the oil pump using the procedure on page 71 25 Stop the engine Check for oil leaks 26 Check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 27 Reinstall the dipstick 28 Discard used oil and filter properly Safe Add Oil Safe Range ...

Page 73: ... 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 Remove the vent line clamp If the line is bled properly you should hear a rush of air If you do not hear a rush of air repeat the priming procedure Clamp Pressure Relief Slit Tank 5 cm ...

Page 74: ...Recommendations 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 overfill 5 Reinstall the fill plug Torque to specification Lubricant Oil Change Capacity Fill Plug Torque Drain Plug Torque Premium AGL Synthetic Gearcase Lubricant 948 ml 30 N m 30 N m Oil Level ...

Page 75: ...n 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 72 8 Add the recommended oil See page 72 9 Reinstall the fill plug Torque to specification See page 72 10 Check for leaks 11 Discard used oil properly ...

Page 76: ...e 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 fluid as needed 5 Reinstall the fill plug Torque to specification Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Demand Drive LT Premium Fluid 275 ml 11 14 N m 15 N m D...

Page 77: ...he 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 74 7 Add the recommended fluid 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly ...

Page 78: ...e page 118 for the part numbers 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 recommended fluid as needed DO NOT use brake fluid 6 Maintain the fluid level between the minimum and maximum marks Do not over fill ADC Fluid Reservoir ...

Page 79: ...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 fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir wi...

Page 80: ...ee page 118 for the part num bers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level drop on new machines is normal as the system is purging itself of trapped air Add coolant as needed Check the coolant level in the radiator any time the recovery bottle has run dry Add coolant as nee...

Page 81: ...cover 2 Open the access door 3 Remove the radiator pressure cap 4 If coolant is not visible slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 6 Secure the access door and box cover Radiator Cap ...

Page 82: ...rs of Polaris products An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ...

Page 83: ...t overfill 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 The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Master Cylinder Indicator Window Full Low ...

Page 84: ...vehicle on a level surface 2 Remove the seat 3 View the fluid level in the reservoir 4 Remove the cap and add the recommended fluid as needed 5 Maintain the fluid level between the minimum and maximum marks Do not overfill 6 Reinstall the reservoir cap 7 Reinstall the seat Minimum Maximum Brake Fluid Reservoir ...

Page 85: ...rake 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 80 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check t...

Page 86: ...two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire TIP 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 more than the front mea surement on each side of the vehicle to obtain the recomme...

Page 87: ...ng in loss of control 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 4 Be sure the handlebars do not con tact the gas tank or any other part of the machine when turned fully to the left or right 5 Torque the front two bolts to 14 17 N m then torque the re...

Page 88: ...ll the panel outward to disengage the side panel from the grommet 4 Pull the panel downward and rearward to remove it Footwell Removal 1 Remove the six screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Screws Rivets ...

Page 89: ...Loosen 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 Move the throt tle lever back and forth while adjusting 5 Tighten the lock nut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position 7 Engine RPM should not increase when steering is turned full left or right Readjust cable fre...

Page 90: ...es Refer to the specifications section beginning on page 116 for recom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Nut Torque Specifications C...

Page 91: ...n 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 wheel 7 Place the wheel on the hub 8 Install the wheel nuts finger tight 9 Lower the vehicle to the ground 10 Torque the wheel nuts to specification See torque chart on page 88 ...

Page 92: ...t lined in the Periodic Maintenance Chart beginning on page 61 1 Position the vehicle 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 filter from the filter 9 Wash the pre filter in soapy water Rinse and air dry Replace the fil ter if needed 10 Reverse the...

Page 93: ...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 leaks Replace as needed 5 Reinstall the filter and hose clamps The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause ...

Page 94: ...ce from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 4 Start the engine Turn the head light switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the lower headlight screws to adjust the beam upwar...

Page 95: ...will shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position 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 ...

Page 96: ...nts in reverse order Front Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Remove the lens attachment screws 3 Rotate the lamp to remove it 4 Install the new lamp 5 Reinstall the lens Rear Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Rotate the turn signal socket counter clockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install th...

Page 97: ...ent 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 Install a new fuse with the same amperage 4 Secure the access door 5 Secure the box cover Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A Main Fuse Ignition Lighting 20A Accessories 12V Power Receptacle Fuse Panel Fuses 5or6 15 20 20 ...

Page 98: ...own 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 The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the fir...

Page 99: ...e 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 specification before installation 5 Reinstall the spark plug Torque to specification See page 96 6 Reinstall the spark plug cap ...

Page 100: ... further operation perform the following pro cedure NOTICE If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 1 Move the vehicle out of the water 2 Remove the spark plug 3 Drain any water found in the air box ...

Page 101: ...y the spark plug Reinstall the plug or install a new plug 6 Torque to specification See page 96 7 Attempt to start the engine If necessary repeat the drying procedure 8 Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not 9 If water has been ingested into the PVT follow the procedure on page 103 for drying out the PVT ...

Page 102: ...le it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Occasionally the spark arrestor may accumulate carbon which can restrict the exhaust if left unattended Purge the spark arrestor 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the ...

Page 103: ...let 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 steps 5 to 7 until no more particles are expelled 10 Stop the engine Allow the arrestor to cool 11 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 30 cm ...

Page 104: ... 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 following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on ...

Page 105: ...ter 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 Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 7 Test for belt slippage If the belt slips repeat the process 8 Ta...

Page 106: ...d eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is ...

Page 107: ... soda and one cup water to prevent damage to the vehicle Battery Installation 1 Ensure that the battery is fully charged Place the battery in the bat tery holder 2 With conventional batteries install the battery vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte Battery gases could accu...

Page 108: ...ge 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 will automatically charge the battery if the voltage drops below a pre determined point See page 118 for the part numbers of Polaris products Battery Fluid Conventional Battery Check the battery fluid level often Mai...

Page 109: ...e 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 installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this b...

Page 110: ...may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts No...

Page 111: ...plastic 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 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 washer to clean the vehicle Do not use medium ...

Page 112: ...aler 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 water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Fo...

Page 113: ... 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 periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the produ...

Page 114: ...atment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter Se...

Page 115: ...ill Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 112 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 Apply dielectric grease to the inside of each spark plug cap Rein stall the caps 5 Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ...

Page 116: ...ightly 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 condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris als...

Page 117: ...nt loss during transporting 5 Always tie the frame of the Tractor to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars Towing a Disabled Vehicle If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt Always attach the tow rope to the frame of ...

Page 118: ...48 in 122 cm Overall Height 48 in 122 cm Wheelbase 50 5 in 128 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Fuel Capacity 4 12 gal 15 6 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 ml Transmission Oil Capacity 32 oz 948 ml Engine EH50PLE Displacement 498 cc Bore x Stroke 92mm x 75mm Alternator Output 350 w C...

Page 119: ... 5 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 beam on bumper 37 5 watt Parking Lights 5 watts Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 10 WH PN 563...

Page 120: ...mand Drive LT Premium Fluid 237 ml 2870465 Pump for 3 8 liter jug 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 Premium All Season Grease 89 ml cartridge 2871423 Premium All Season Grease 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 89 ml 2871551 Premium U Joint Lube 414 m...

Page 121: ...speed 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 Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See pa...

Page 122: ...e 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 Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range S...

Page 123: ...attery 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 malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean...

Page 124: ...et 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 speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engi...

Page 125: ...Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE No verification of reg istration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not...

Page 126: ...tible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY D...

Page 127: ...BILITY 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 issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which va...

Page 128: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 129: ...127 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 130: ...me 34 Clothing 9 Clutching 117 C Cold Weather Operation 43 Coolant Bottle 78 Coolant Radiator 79 Cooling System 78 79 Corrosion Removal Chrome 111 D Demand Drive Fluid 74 75 Disengaging Active Descent Control 30 Drive Belt Wear Burn 119 Drivetrain Break In 40 Driving Downhill 49 Driving in Reverse 56 Driving on a Sidehill 48 Driving on Slippery Surfaces 54 Driving Over Obstacles 55 Driving Procedu...

Page 131: ...ves 9 H Hand Brake 81 Handlebar Adjustment 85 Hauling Cargo 57 59 Hazard Warning Switch 22 Headlight Lamp 93 Helmet 8 High Beam Adjustment 92 High Range Use 43 H Hitches 26 Horn Switch 22 Hub Tightening 88 I Immersion 99 Immersion Maintenance 98 Instrument Cluster 31 39 K Key Switch 21 K Turn 50 51 L Light Switch High Low Beam 21 Light Switch Master 20 Lights 92 94 Brake Light 94 Front Turn Signal...

Page 132: ...17 Rack Warning 19 Reverse Override Alert 18 Tire Pressure Load Alert 18 S Safety Training 7 Seat 25 Backrest Adjustment 25 Height Adjustment 25 Load Adjustment 25 Seat Removal 25 Service Interval Programming 36 Severe Use 61 Side Panel Removal 86 Sidehilling 48 Signal Words 4 Spark Arrestor 100 101 Spark Arrestor Requirements 60 Spark Plug Inspection 96 Spark Plug Recommendations 96 Spark Plug To...

Page 133: ...y 7 Transmission 27 Transmission Oil 72 73 Transporting the Vehicle 115 Turn Signal Lamp Front 94 Turn Signal Lamp Rear 94 Turn Signal Switch 22 Turning Around on a Hill 50 51 Turning the Vehicle 45 V Vehicle Identification Numbers 6 Vehicle Immersion 98 99 VIN 6 W Warning Symbols 4 Washing the Vehicle 109 110 Wheel Installation 89 Wheel Nut Torque Specifications 88 Wheel Removal 89 ...

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Polaris Sportsman 9921837, Owner'S Manual

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