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Polaris Sportsman 9921848 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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  • Page 2 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles • RANGER utility vehicles •...
  • Page 3 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 4: Table Of Contents

    Specifications ......126 Polaris Products..... . . 128 Troubleshooting .

  • Page 6: Know Your Vehicle

    Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.

  • Page 7: Safety

    Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 8: Safety Training

    Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
  • Page 9 Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 10 SAFETY Rider Safety Never allow a passenger to ride in the cargo box. Always wear an approved helmet that fits 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 Quadricycle.
  • Page 11 SAFETY Rider Safety Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 45. Keep both hands on the handlebars. Keep both feet on the footrests. A passenger should always be seated in the passenger seat with both feet on the footrests and both...
  • Page 12 SAFETY Rider Safety If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Always follow the procedures outlined in this manual for driving on hills.
  • Page 13 SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 56. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 14 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving in reverse. See page 63. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Quadricycle through improper installation or use of accessories.
  • Page 15 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 Quadricycle safety, contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 16: General Alert

    Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 17: Tire Pressure/Load Alert

    SAFETY Safety Decals and Locations Reverse Override Alert Front Rack Warning Clutch Warning Cover Alert Tire Pressure/ Load Alert Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 514 LBS. (233 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES.

  • Page 18: Box Warning

    SAFETY Safety Decals and Locations Box Warning WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 348 lbs. (158 kg) Clutch Cover Alert NO STEP Front Rack Warning...

  • Page 19: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 20: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 21: Features And Controls

    Switches Mode/Reverse Override Switch Engine Stop Switch Headlight Switch Horn Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 34. To gain additional power while operating in reverse, press the override switch before opening the throttle.

  • Page 22: Light Switch

    Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position.

  • Page 23: X4 Switch

    Switches 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 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 situation requiring caution.

  • Page 24: Differential Switch

    Switches Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns.

  • Page 25: Throttle Lever

    Throttle Lever Press the throttle lever to increase engine speed and vehicle move- ment. Release the lever to reduce engine speed and vehicle move- ment. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine.

  • Page 26: Foot Brake

    Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

  • Page 27: Parking Brake

    FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze the brake lever toward the 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.
  • Page 28 FEATURES AND CONTROLS Recoil Starter (if equipped) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 46, cranking the engine with the recoil Handle starter instead of the main key switch.

  • Page 29: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. 1. Turn the handlebars to the full right position. NOTE: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise.
  • Page 30 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector Gear is located on the right side of Selector 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.
  • Page 31 FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

  • Page 32: Disengaging Active Descent Control

    FEATURES AND CONTROLS All Wheel Drive (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

  • Page 33: Passenger Seat

    FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when oper- ating without a passenger. Always return the seat to the 1-up position for single-rider operation.

  • Page 34: Seat Conversion

    NOTE: If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. 8. To return the vehicle to single-rider operation, reverse all steps. Always lower the passenger backrest to the lowest position before folding it down into the cargo box.

  • Page 35: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.

  • Page 36: Rider Information Center

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear...
  • Page 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or kilometers traveled by the Quadricy- cle.
  • Page 38 Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4).
  • Page 40 Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

  • Page 41: Diagnostic Mode

    Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 42 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 42 Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.
  • Page 43 Instrument Cluster Rider Information Center Downloading Codes Blink Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage...

  • Page 44: Operation

    Fuel Safety 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 a spark.

  • Page 45: Break-In Period

    Break-In Period The break-in period for your new Polaris Quadricycle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and perfor- mance of your Quadricycle more than following the procedures for a proper break-in.

  • Page 46: Pre-Ride Checklist

    Ensure proper operation Adjust for best side/rear vision Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 47: Starting The Engine

    OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.

  • Page 48: Cold Weather Operation

    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.

  • Page 49: Driving Procedures

    OPERATION Driving Procedures 1. Wear protective riding gear. See page 18. 2. Perform the pre-ride inspection. See page 45. 3. Place the transmission in PARK. 4. Mount the vehicle from the left side. 5. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars.

  • Page 50: Turning The Vehicle

    Turning the Vehicle 1. Before turning, activate a turn sig- nal to alert others of your inten- tions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while support- ing your weight on the outer foot-...

  • Page 51: Driving With A Passenger

    OPERATION Driving with a Passenger Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle. Never carry more than one passenger on this 2-up Quadricycle.
  • Page 52 Driving with a Passenger 6. Mount the vehicle from the left side. 7. After the operator is seated, the passenger should mount the vehicle from the left side. NOTE: Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab han- dles at all times.

  • Page 53: Driving Uphill

    OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 2. Avoid steep hills (15° maximum). 3. Avoid hills with slippery or loose surfaces. 4.
  • Page 54 Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3.
  • Page 55 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. If operating in 2X4 mode, make sure the differential is locked ( ). 3.

  • Page 56: Driving Downhill

    Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed.
  • Page 57 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 58 Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. NOTE: A passenger should not remount until the vehicle returns to level ground. 11. Apply the foot brake. 12.

  • Page 59: Driving Through Water

    OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 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.
  • Page 60 OPERATION Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 106. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water.

  • Page 61: Driving On Slippery Surfaces

    Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage 4X4 before wheels begin to lose traction. 3. Be alert. 4.

  • Page 62: Driving Over Obstacles

    OPERATION Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 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.

  • Page 63: Parking On An Incline

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

  • Page 64: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4.

  • Page 65: Hauling Cargo

    Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Never exceed the stated load capacity for this vehicle. •...
  • Page 66 Hauling Cargo Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle. 1. Always load the cargo box with the load as far forward as possible. 2. Slow down. 3.

  • Page 67: Towing Loads

    Hauling Cargo Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Avoid towing on inclines. Do not exceed the maximum capacities when towing. If towing a load, reduce cargo bed weight by the amount of tongue weight.

  • Page 68: Dumping Cargo

    Hauling Cargo Dumping Cargo 1. Position the vehicle on a level surface. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Dismount the vehicle. 4. Lower the tailgate. If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury.

  • Page 69: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 70: Maintenance

    Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 34. Record maintenance and service in the Maintenance Log beginning on page 136.

  • Page 71: Maintenance Chart Key

    Perform these operations more often for vehicles subjected to severe use. E Emission-related service Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
  • Page 72 Periodic Maintenance Chart Item Air filter, main element Recoil housing Brake pad wear Battery Demand drive fluid Rear gearcase oil (if equipped) Transmission oil Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Shift linkage Steering Front suspension Rear suspension Throttle cable/ ETC switch...
  • Page 73 Fuel filter Spark arrestor Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Kilometers 12 M 1600...

  • Page 74: Lubrication Guide

    Item Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Brake Fluid DOT 4 Only Transmission Oil Polaris AGL Synthetic Gearcase Lube Demand Drive Demand Drive LT Pre- Fluid (Front mium Fluid Gearcase) ADC Fluid Polaris ADC Fluid...

  • Page 75: Engine Oil

    Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may 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-...

  • Page 76: Oil Level

    Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth.

  • Page 77: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds.
  • Page 78 Engine Oil Oil and Filter Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12.
  • Page 79 MAINTENANCE Engine Oil Oil and Filter Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. NOTE: If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24.

  • Page 80: Oil Pump Priming

    Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been 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.

  • Page 81: Transmission Oil

    Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 128 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Premium AGL Synthetic Gearcase Lubricant Transmission Oil Level 1.

  • Page 82: Transmission Oil Change

    Transmission Oil Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission 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.

  • Page 83: Fluid Level

    Use the recommended fluid. Fill Plug Use of other fluids may result in improper operation of components. See page 128 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole Fill Level threads. Drain Plug Fluid Level 1.
  • Page 84 Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the 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.
  • Page 85 Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 128 for the part numbers of Polaris products. Fluid Level 1.

  • Page 86: Fluid Change

    Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

  • Page 87: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 128 for the part num- bers of Polaris products.

  • Page 88: Radiator Coolant

    Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box 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.

  • Page 89: Brake Fluid

    If the fluid level is low add DOT 4 brake fluid only. See page 128 for the part numbers 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.
  • Page 90 Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.
  • Page 91 MAINTENANCE Brake Fluid Foot Brake The foot brake fluid reservoir is located under the front box. The brake fluid reservoir cap is black. 1. Position the vehicle on a level surface. 2. Open the front box cover. 3. Open the access door. 4.

  • Page 92: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 93: Toe Alignment

    3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING Stand String...

  • Page 94: Handlebar Adjustment

    Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference.

  • Page 95: Side Panel Removal

    MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it.

  • Page 96: Throttle Cable Freeplay

    Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 97: Tire Tread Depth

    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 Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service.
  • Page 98 Tires Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 1. Position the vehicle on a level surface. 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.

  • Page 99: Air Filter

    MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals out- lined in the Periodic Maintenance Chart beginning on page 69. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 100 Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 94. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3.

  • Page 101: High Beam Adjustment

    Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 102 Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 103 Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6.

  • Page 104: Fuse Replacement

    Lights Taillight/Brakelight Lamp Replacement 1. Open the tailgate. 2. Remove the two screws near the tail- gate latch. 3. Grasp the entire taillight assembly and pull it away from the vehicle. 4. Remove the harness connector from the back of the light assembly. 5.

  • Page 105: Spark Plugs

    Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 126 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.
  • Page 106 Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 94. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup.

  • Page 107: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro- cedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
  • Page 108 Vehicle Immersion 4. Turn the ignition key past the POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 104.

  • Page 109: Spark Arrestor

    MAINTENANCE Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas.
  • Page 110 Spark Arrestor 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet 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.

  • Page 111: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 112: Pvt Drying

    PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.

  • Page 113: Recoil Housing

    Recoil Housing Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 1. Place the transmission in PARK. 2. Stop the engine. 3.
  • Page 114 Battery 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.

  • Page 115: Battery Removal

    Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 116: Battery Installation

    Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed bat- teries do not have a vent tube). NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent con- tact with electrolyte.

  • Page 117: Battery Storage

    NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 118 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 114. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 119 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

  • Page 120: Cleaning And Storage

    Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 121: Polishing The Vehicle

    • Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 122 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 123: Storage Tips

    Make any necessary repairs and clean the vehicle as recommended. See page 119. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...
  • Page 124 Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
  • Page 125 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.

  • Page 126: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope.

  • Page 127: Specifications

    350 w 10.2:1 Electronic Fuel Injection Electronic Ignition 10 +/- 1 BTDC @ idle NGK BKR6E .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Dry Sump Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.75" (22 cm) travel...
  • Page 128 Sportsman 500 X2 Quadricycle Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching (EBS Models) Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000)

  • Page 129: Polaris Products

    Chain Lube, Aerosol (185 ml) 2872348 Chain Lube, Aerosol (473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 130: Troubleshooting

    Dry out the PVT. See page 111. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 48 km/h for 1.6 km.
  • Page 131 Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...
  • Page 132 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 133: Engine Overheating

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter...

  • Page 134: Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer 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 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 QUADRICYCLE.
  • Page 135 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any Quadricycle...
  • Page 136 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 137: Maintenance Log

    MAINTENANCE LOG Present this 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 TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 138 MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 139: Index

    INDEX Numeric 4X4 System ....30-31 Accessories ....124 Active Descent Control Fluid .
  • Page 140 Passenger Seat ....32-33 Periodic Maintenance Chart ..69-72 Polaris Product List... . . 128 Polishing the Vehicle ... 120 Position Light Lamp .
  • Page 141 Safety Decals Age 16 Alert ....15 Box Warning ....17 General Alert ....15 Hill Operation Alert.

This manual is also suitable for:

2009 sportsman 500 x2

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