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SPECIFICATIONS

* Based on EU Directive 76/432/EC

SPORTSMAN 500 Touring International

Maximum Weight Capacity

568 lbs. (258 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

791 lbs. (359 kg)

Front Rack/Storage Box Capacity 90 lbs. (41 kg)
Rear Rack Capacity

180 lbs. (82 kg)

Receiver Hitch Tongue Capacity

120 lbs. (54.4 kg) (Rear rack capacity and tongue

weight not to exceed 180 lbs. (82 kg)

Hitch Towing Rating

1225 lbs. (555.7 kg)

Unbraked Trailer Towing

Capacity*

1995 lbs. (905 kg)

Overall Length

86 in. (218 cm)

Overall Width

48 in. (122 cm)

Overall Height

48 in. (122 cm)

Wheelbase

57 in. (145 cm)

Ground Clearance

11 in. (28 cm)

Minimum Turning Radius

82 in. (208 cm) unloaded

Fuel Capacity

5.4 gal. (20.5 l)

Engine Oil Capacity

2 qts. (1.9 l)

Coolant Capacity

2.7 qts. (2.5 l)

Demand Drive Fluid Capacity

9.3 oz. (275 ml)

Transmission Oil Capacity

32 oz. (948 ml)

Engine

EH50PLE

Displacement

499 cc

Bore x Stroke

92mm x 75mm

Alternator Output

350 w

Compression Ratio

10.2:1

Carburetor

40mm Mikuni

Pilot Jet

Main Jet

155

Needle Jet

X-6M

Jet Needle

6MGHI 194

Pilot Screw

By flow (taper 12.5

) (Brass Plug)

Ignition System

Digital CDI

Ignition Timing

+/- 2

@ 5000 RPM

Spark Plug

NGK BKR6E

Spark Plug Gap

.035+0.0/-0.004 in. (0.9+0.0/-0.1 mm)

Lubrication System

Dry Sump

Содержание Sportsman 9922551

Страница 1: ...y It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety 2010 Pantone 426c Sportsman 5...

Страница 2: ...eitung bevor Sie dieses Fahrzeug bedienen oder fahren Antes de operar o conducir este veh culo lea el Manual del propietario Lire le Manuel d utilisation avant d utiliser ou de conduire ce v hicule Pr...

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

Страница 4: ...s 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 Manua...

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

Страница 6: ...ion 4 Safety 7 Features and Controls 20 Operation 37 Emission Control Systems 60 Maintenance 61 Specifications 118 Polaris Products 120 Troubleshooting 121 Declaration of Conformity 125 Warranty 126 M...

Страница 7: ...l injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may...

Страница 8: ...rom a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone...

Страница 9: ...using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ F...

Страница 10: ...le any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris vehicle is terminated if any equipme...

Страница 11: ...bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distin...

Страница 12: ...sonal 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 p...

Страница 13: ...d instructor Contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate the vehicle unless they have read and understand this manual...

Страница 14: ...fore or while operating this vehicle Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience Never attempt jumps or...

Страница 15: ...lways travel slowly when operating on unfamiliar terrain Use extra caution Use caution when operating on rough slippery or loose terrain Always follow the procedures outlined in this manual for turnin...

Страница 16: ...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...

Страница 17: ...ned 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 w...

Страница 18: ...icle 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 ins...

Страница 19: ...ine Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is s...

Страница 20: ...afety decals are provided by Polaris at no charge The part number is printed on the decal The following pages repeat the information found on each decal General Alert Multi Lingual Before you operate...

Страница 21: ...ND ACCESSORIES Read Owner s Manual for more detailed loading information Reverse Override Alert Pushing reverse override button may cause sudden increases in power and traction if too much throttle is...

Страница 22: ...g Front and Rear WARNING WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 lbs 41...

Страница 23: ...This will cancel the reverse speed limit function Tip 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...

Страница 24: ...ey fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could resul...

Страница 25: ...age 4X4 or 2X4 See page 30 Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously Use this feature to alert others of an emergency or other situat...

Страница 26: ...ch 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 Swit...

Страница 27: ...t start or operate the vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Mirrors Use the mirrors to assist in traffic maneuvers...

Страница 28: ...rates 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 Aggres...

Страница 29: ...e handlebar 3 Push the parking brake lock forward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever Operating the vehicle while the par...

Страница 30: ...abruptly to start the engine Extending the recoil starter rope until it stops can cause damage to the recoil assembly If the starter rope handle is not seated properly water may enter the recoil hous...

Страница 31: ...lost 4 Reverse the procedure to unlock the steering The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine Fuel Tank C...

Страница 32: ...idling move the lever to the desired gear See your dealer if you experience any shifting problems Passenger Seat Always make sure the passenger seat is installed and securely latched before operating...

Страница 33: ...nit 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...

Страница 34: ...he vehicle may 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 wh...

Страница 35: ...n addition to showing vehicle speed the speedometer needle flashes when a warning condition exists High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose usin...

Страница 36: ...Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is...

Страница 37: ...s or kilometers traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total ch...

Страница 38: ...n Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens Battery Voltage Screen View this screen to check battery voltage level Tachomete...

Страница 39: ...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...

Страница 40: ...use Engine and Drivetrain Break in 1 Fill the fuel tank with the recommended fuel See page 28 2 Check the engine oil level See page 66 Add oil if necessary 3 Select an open area that allows room to fa...

Страница 41: ...87 89 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 28 66 Coolant level if applicable Ensure proper level 76 77 Coolant hoses if applicable Inspect for leaks T...

Страница 42: ...the transmission is in gear and the brake is not engaged 5 Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 If the engine is c...

Страница 43: ...engine to warm up for several minutes before operating the vehicle 12 If a warm engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out ma...

Страница 44: ...damage Any condensation must be drained Always operate the engine long enough to reach operating temperature which reduces condensation See your Polaris dealer for engine heater kits which provide qui...

Страница 45: ...ep your feet on the footrests Keep both hands on the handlebars 6 Start the engine and allow it to warm up 7 Apply the brakes 8 Shift the transmission into gear 9 Check your surroundings and determine...

Страница 46: ...n leaning your upper body to the inside of the turn while support ing your weight on the outer foot rest Use the same leaning technique for turning in reverse 3 Never turn quickly when carrying a pass...

Страница 47: ...icle 1 Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles 2 Make sure the passenger is wearing appropriate riding gear including...

Страница 48: ...time and distance for braking 9 Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle 10 Do not cross a hillside with a passenger on board See page 48 11 Nev...

Страница 49: ...aces 3 Keep both feet on the footrests 4 Shift body weight uphill 5 Drive straight uphill 6 Proceed at a steady rate of speed to avoid stalling 7 Be alert Be prepared to take emergency action This may...

Страница 50: ...c parking brake 3 A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Use the K turn to turn...

Страница 51: ...board Ask the passenger to dismount and walk across the hillside 5 Shift your weight uphill 6 Keep your feet on the footrests 7 Steer slightly into the hill 8 If the vehicle begins to tip quickly tur...

Страница 52: ...ing downhill at an angle which can cause the vehicle to pitch sharply to one side 4 Shift your weight rearward 5 Apply the brakes slightly to aid in slowing Always follow the procedures outlined in th...

Страница 53: ...rward gear Turn the engine off 4 A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 5 Stay up...

Страница 54: ...tart the engine 12 Squeeze and release the brake lever to release the parking brake 13 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehic...

Страница 55: ...les 4 Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward mot...

Страница 56: ...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 vehicl...

Страница 57: ...atch the trail 5 Avoid quick sharp turns 6 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 7 Never apply the brakes during a skid Always fol...

Страница 58: ...rea 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches 5 Always have a passenger dismount before operating over an...

Страница 59: ...g on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 4 Turn...

Страница 60: ...owly Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the throttle suddenly 6 Do not use the override switch unless additional power is required for vehicle movement...

Страница 61: ...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 vehicl...

Страница 62: ...e combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum wei...

Страница 63: ...Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maint...

Страница 64: ...rtant 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 w...

Страница 65: ...ance Interval whichever comes first Remarks Hours Calendar Kilometers Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 38 Front suspension Pre Ride Rear suspension Pre Ride...

Страница 66: ...at one month X General lubrication 50 3 M 800 Lubricate all fittings pivots cables etc Carburetor float bowl 50 6 M 800 Drain bowl periodically and prior to storage Shift linkage 50 6 M 800 Inspect lu...

Страница 67: ...hoses 100 12 M 1600 Inspect 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 Ins...

Страница 68: ...severe use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l See...

Страница 69: ...need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation Mixing brands or using a non recommended...

Страница 70: ...ngine Allow it to idle for 30 seconds 4 Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil a...

Страница 71: ...the transmission in PARK 3 Start the engine Allow it to idle for 30 seconds 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 D...

Страница 72: ...4 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 Lubric...

Страница 73: ...rs 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 n...

Страница 74: ...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...

Страница 75: ...ecommendations Transmission Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Check the oil level Add the recommended oil as needed Do not o...

Страница 76: ...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...

Страница 77: ...the 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...

Страница 78: ...e transmission in PARK 3 Remove the fill plug 4 Remove the drain plug Drain the fluid into a drain pan 5 Clean the drain plug 6 Reinstall the drain plug Torque to specification See page 74 7 Add the r...

Страница 79: ...page 120 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 d...

Страница 80: ...ox 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 6 Secure the access door...

Страница 81: ...s 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 Und...

Страница 82: ...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...

Страница 83: ...ion 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 NOTICE Always use...

Страница 84: ...ake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 78 2 Check the brake systems regular...

Страница 85: ...wo 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...

Страница 86: ...trol 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 B...

Страница 87: ...for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Rear Spring The rear shock absorber spring is adjusted by rotating the adjus...

Страница 88: ...panel from the grommet 4 Pull the panel downward and rearward to remove it 5 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the six screws...

Страница 89: ...osen 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...

Страница 90: ...riginal equipment size and type when replacing tires Make sure the wheels are installed properly Replace tires when the tread depth measures 3 mm or less Refer to the specifications section beginning...

Страница 91: ...Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 122 Nm 2 Piece Flange Nut 37 Nm Cast Alumin...

Страница 92: ...ce 2 Place the transmission in PARK 3 Loosen the wheel nuts slightly 4 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 5 Remove the wheel nuts 6 Remove the w...

Страница 93: ...hicle 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 fi...

Страница 94: ...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...

Страница 95: ...from the floor to the center of the headlight and make a mark on the wall at the same height Tip Include rider weight on the seat when measuring 4 Start the engine Turn the head light switch to high b...

Страница 96: ...ill 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 t...

Страница 97: ...verse order Front Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Remove the lens attachment screw 3 Rotate the lamp to remove it 4 Install the new lamp 5 Reinstall the lens Rear Turn...

Страница 98: ...fuse may need replacement Tip Spare fuses are provided in a compart ment 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 I...

Страница 99: ...ll 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 ind...

Страница 100: ...spark plug wrench to remove the spark plug Turn the plug counterclockwise to remove it 4 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at spec...

Страница 101: ...pro cedure If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 1 Move the v...

Страница 102: ...Reinstall the plug or install a new plug 8 Torque to specification See page 96 9 Tighten the carburetor drain screw 10 Turn the fuel valve on 11 Attempt to start the engine If necessary repeat the dr...

Страница 103: ...are required for operation above 1800 meters and at temperatures below 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or...

Страница 104: ...letely dry before reinstalling the drain plug 1 Place the transmission in PARK 2 Stop the engine 3 Remove the drain screw on the bottom of the recoil housing 4 Allow the housing to drain com pletely 5...

Страница 105: ...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...

Страница 106: ...et while repeat ing step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels 9 Place the transmission in PARK Repeat...

Страница 107: ...oads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product...

Страница 108: ...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 Tip Do not hold the throttle wide o...

Страница 109: ...uce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicl...

Страница 110: ...ttery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away...

Страница 111: ...sing a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charg...

Страница 112: ...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 a...

Страница 113: ...using a constant current charger use the following guidelines for recharging Tip Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge T...

Страница 114: ...e 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 f...

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

Страница 116: ...t 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 periodic...

Страница 117: ...he 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...

Страница 118: ...n See page 114 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...

Страница 119: ...ly 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...

Страница 120: ...e the key to prevent loss during transporting 6 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pock...

Страница 121: ...Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 5 4 gal 20 5 l Engine Oil Capacity 2 qts...

Страница 122: ...8 12 5 psi 34 5 KPa Tires Pressure Rear 25x11 12 5 psi 34 5 KPa Brake Hand All wheel hydraulic disc Brake Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all whee...

Страница 123: ...nd Drive Hub Fluid 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 l Coolant 2871323 60 40 Coolant 3 8 l 2871534 60 40 Coolant 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All S...

Страница 124: ...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 thr...

Страница 125: ...ctive 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 Overuse of choke...

Страница 126: ...lugged 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...

Страница 127: ...ark plug gap or heat range Set 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...

Страница 128: ...009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH...

Страница 129: ...egistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of regist...

Страница 130: ...to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty...

Страница 131: ...abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatibl...

Страница 132: ...ealer authorized to repair Polaris vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALE...

Страница 133: ...ection of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE KILOMETERS OR HOURS TEC...

Страница 134: ...131 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 135: ...nt Radiator 77 Cooling System 76 77 Corrosion Removal Chrome 113 D Demand Drive Fluid 74 75 Drive Belt Wear Burn 121 Drivetrain Break In 37 Driving Downhill 49 Driving in Reverse 57 Driving on a Sideh...

Страница 136: ...mersion Maintenance 98 Instrument Cluster 32 36 J Jetting Chart 119 K Key Switch 21 K Turn 50 51 L Light Switch 21 Lights 92 94 Front Turn Signal 94 Headlight Lamp 93 High Beam Adjustment 92 Position...

Страница 137: ...ifications 118 119 Spring Adjustment Rear Shock 84 Starting the Engine 39 40 Steering Assembly 84 Steering Lock 28 Storage 111 116 Storage Tips 114 116 S Switches 20 23 4X4 Switch 22 Engine Stop Switc...

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