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Polaris 9922551 Offroad Vehicle User Manual

1. e Coolant test strength fill Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean 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 Rein stall the caps 5 Turn the engine over several times using the recoil starter if equipped 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 carburetor should be completely drained of gasoline 7 To eliminate any fuel remaining in the carburetor run the engine until it stops 115 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 61 Battery Storage See pages 108 109 for storage and charging procedures Storage Area Covers 1 Set the tire pressure and safely support the vehicle with the tires slightly off the ground 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 powe
2. 2873603 Premium AGL Synthetic Gearcase Lube 3 8 2877922 Demand Drive Plus Fluid 95 I 2877923 Demand Drive Plus Fluid 3 8 I 2870465 Pump for 3 8 liter jug 2871654 Premium Demand Drive Hub Fluid 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 I Coolant 2871323 60 40 Coolant 3 8 I 2871534 60 40 Coolant 95 I 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 ml 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 185 ml 2872348 Chain Lube Aerosol 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 120 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range Starting out going up a steep incline Use low range or turn around using the K turn see page 50 Driving at low RPM or ground speed 5 11 kmh Drive at a higher speed or use low range more frequently Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in sho
3. Footwell Removal l 2 3 Remove the footwell Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it When reinstalling side panels align the fasteners and press firmly to secure them Remove the six screws on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 85 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar a 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Boot gt 3 Loosen the adjuster lock nut Lock Nut Adjuster 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 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Tip Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs 86 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehi
4. Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Headlight taillight Daily Check operation apply dielectric grease if replacing lamps 62 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Kilometers gt Air filter Weekly Inspect replace as needed E main element Recoil housing if Weekly Drain water as needed equipped check often if operating in wet conditions gt Brake pad wear 10 Monthly 160 Inspect periodically E Battery 20 Monthly 320 Check terminals clean test gt Demand drive fluid 25 Monthly 400 Inspect level change yearly gt Rear gearcase oil 25 Monthly 400 Inspect level change yearly if equipped gt Transmission oil 25 Monthly 400 Inspect level change yearly gt Engine breather 25 Monthly 400 Inspect clean if needed E filter if equipped gt Engine oil change 1M Perform a break in oil change break in at one month gt General 50 3M 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50 6M 800 Drain bowl periodically and bowl prior to storage Shift linkage 50 6M 800 Inspect lubricate adjust E Steering 50 6M 800 Lubricate gt Front suspension 50 6M 800 Lubricate
5. Tank 5cm lt _ gt Clamp Pressure Relief Slit 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 71 MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads Use the recommended oil See page 120 for the part numbers of Polaris products Transmission Oil Recommendations Lubricant Oil Change Fill Plug Drain Plug Capacity Torque Torque Premium AGL Synthetic 948 ml 30 N m 30 N m Gearcase Lubricant Transmission Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the oil level Add the recommended oil as needed Do not overfill 5 Reinstall the fill plug Torque to specification Pe Oil Level 72 MAINTENANCE Transmission Oil Transmission Oil Change l 2 10 11 Position the vehicle on a level surface Place the transmission in PARK Remove the fill plug Remove the drain plug Drain the oil into a drain pan Clean the drain plug Reinstall the drain plug Torque to specification See page 72 Add the recommended oil See page 72 Reinstall the fill plug Torque to specification See page 72 Check for leaks Discard used oil properly 73 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Recomm
6. gt Rear suspension 50 6M 800 Lubricate E Throttle cable 50 6M 800 Inspect adjust lubricate E ETC switch replace if necessary E Choke cable 50 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50 6M 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50 6M 800 Inspect adjust replace as needed Cooling system 50 6M 1600 Inspect coolant strength seasonally pressure test system yearly gt Engine oil change 100 6M 1600 Perform a break in oil change at one month gt Oil filter change 100 6M 1600 Replace with oil change gt Oil tank vent hose 100 6M 1600 Inspect routing condition if equipped 63 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Kilometers z Valve clearance 100 12 M 1600 Inspect adjust E Fuel system filter 100 12M 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every 2 years gt Radiator 100 12M 1600 Inspect clean external surfaces gt Cooling hoses 100 12M 1600 Inspect for leaks gt Engine mounts 100 12M 1600 Inspect Exhaust muffler 100 12M 1600 Inspect pipe E Spark plug 100 12M 1600 Inspect replace as needed gt Wiring 100 12M 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E
7. Clutches drive 100 12M 1600 Inspect clean replace worn and driven parts E Front wheel 100 12M 1600 Inspect replace as needed bearings E Brake fluid 200 24M 3200 Change every two years gt Fuel filter 200 24M 3200 Replace every 2 years more often under severe use Spark arrestor 300 36 M 4800 Clean out Idle speed Adjust as needed Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 64 Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61 Items not listed in the chart should be lubricated at the General Lubrication interval MAINTENANCE Tip The a arms and upper control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Fluid Front Gearcase Front Prop Shaft Yoke Polaris Premium U Joint Lube Item Lube Capacity at Method Fluid Change Engine Oil PS 4 PLUS Performance 2 qt 1 9 I See page 66 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 78 Transmission Oil Polaris A
8. Hill Operation Alert e Never operate this vehicle on HILLS Age 16 steeper than 15 degrees 15 Alert e To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Operation Alert 17 SAFETY Safety Decals and Locations Reverse Override Front Rack Alert Warning Clutch Rear Rack Cover Alert Warning Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 568 LBS 258 kg INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES Read Owner s Manual for more detailed loading information A Reverse Override Alert 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 See Owner s Manual 18 SAFETY Safety Decals and Locations A Rack Warning 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 Ibs 41 kg Rear 180 Ibs 82 kg Clutch Cover Alert NO STEP 19 FEATURES AND CONTROLS Switches Mode Reverse Override Switch Hazard Switch Switch Horn Switch Turn Signal Switch Mode Reverse Override Switch Press the switch to toggle through the speedometer display modes except in reverse See page 32 To gain ad
9. from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 124 DECLARATION OF CONFORMITY Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 CE We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 EN 55012 2002 M92 EN 61000 6 2 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A KAO OUTLAW 50 2008 2009 2010 76 8 KAO OUTLAW 90 2008 2009 2010 76 8 FAO __ SPORTSMAN 90 2008 2009 2010 76 8 VA RZR 170 2009 2010 81 3 __PB20 __ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 __CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 BA50 __ SCRAMBLER 500 2008 2009 2010 79 6 G OUTLAW 450 2008 2009 2010 80 7 GJ52_ GP52 OUTLAW 525 2008 2009 2010 80 7 __LH27__ SPORTSMAN 300 2008 2009 2010 81 1 LH _ SPORTSMAN 400 2008 2009 2010 80 2 __MNSO__ SPO
10. hill See page 50 13 SAFETY Rider Safety Always 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 Always follow the procedures outlined in this manual for driving in reverse See page 57 14 SAFETY Rider Safety Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure Never modify the vehicle 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 Never operate the vehicle ona frozen body of water 15 SAFETY Rider Safety A Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control Avoid sudden turns or swift movement of the handlebars A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting A A Always unlock the steering before starting the engine S
11. s 23 oaa aaa na 61 Side Panel Removal 85 Sidehilling 48 Signal Words 4 Spark Arrestor 102 103 Spark Arrestor Requirements 60 Spark Plug Inspection 96 Spark Plug Recommendations 96 Spark Plug Torque Specification 96 Spark Plugs 96 97 Specifications 118 119 Spring Adjustment Rear Shock 84 Starting the Engine 39 40 Steering Assembly 84 Steering Lock 28 Storage 0 eee eee 111 116 Storage Tips 114 116 134 S Switches 0 eee wees 20 23 4X4 Switch 0 22 Engine Stop Switch 21 Hazard Warning 22 Hoti ence ee ae aa ae aa 23 Light Switch 21 Main Key Switch 21 Mode Reverse Override Switch 20 Turn Signal 23 T Taillight sy cas foe oy eeeueng 94 Throttle Cable Freeplay 86 Throttle Lever 24 Tire Tread Depth 87 UB OS EEEE E TEE EE 87 89 Wheel Installation 89 Wheel Nut Torque 88 Wheel Removal 89 Toe Alignment 82 Towing a Disabled Vehicle 117 Towing Loads 59 Training Safety 5 Transmission 29 Transmission Oil 72 73 Transporting the Vehicle 117 Turn Signal Lamp Front
12. 94 Turn Signal Lamp Rear 94 Turn Signal Switch 23 Turning Around ona Hill 50 51 Turning the Vehicle 43 V Vehicle Identification Numbers 6 Vehicle Immersion 98 99 MIN EE go ei noite Ee atte ohne sods 6 Ww Warning Symbols 4 Washing the Vehicle 111 112 Wheel Installation 89 Wheel Nut Torque Specifications 88 Wheel Removal 89
13. Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 61 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Enmission related service M Have an authorized Polaris dealer perform these services A Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Kilometers Steering Pre Ride Make adjustments as need 7 7 ed See Pre Ride Checklist Front suspension Pre Ride on page 38 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 Pre Ride latch Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride gt Air filter pre filter Daily
14. battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When 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 Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 110 MAINTENANCE 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 NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage 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 clea
15. connections and tighten Engine Rotates Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Water or fuel in crankcase Inspect plugs verify stop switch is on Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer 122 Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor quality or low octane fuel Replace with recommended fuel Incorre
16. 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 A Switching to 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 while the rear wheels have traction or are at rest 31 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 Speedometer Needle Speedometer Rider Information Center P amp SLARIS In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists A 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 insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 32 FEATURES AND CONTROLS Instrument Cluster Rider
17. dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover if equipped Secure the battery hold down strap SOON IN Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 107 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge 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 See page 120 for the part numbers of Polaris products Battery Fluid Conventional Battery Check the battery fluid level often Maintain the fluid level between the ree eH upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 108 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charg
18. necessary 65 Steering steering lock ea the steering ensure free oper 28 Steering Ensure free operation Tires Inspect condition and pressure 87 Wheels fasteners Inspect ensure fastener tightness ar Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels es Coolant level if applicable Ensure proper level 16 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation aa Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 21 Mirrors Adjust for best side rear vision 24 Air filter pre filter Inspect clean 90 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 93 tric grease when lamp is replaced Brake light taillight Check operation apply Polaris dielec 94 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing 38 OPERATION Starting the Engine A 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 A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating Tip Position the vehicle on a level surface Place the transmission in PARK Turn the fuel valve on Sit on the vehicle The starter interlock
19. or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible 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 DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 128 WARRANTY A
20. procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 47 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 Avoid hills with slippery or loose surfaces Avoid crossing the sides of steep hills e ede es Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside Shift your weight uphill Keep your feet on the footrests Steer slightly into the hill If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately A a BD i Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 48 OPERATION Driving Downhill When driving downhill follow these precautions 1 Avoid hills with slippery or loose surfaces 2 Never drive downhill at high speed Slow down 3 Drive straight downhill Avoid driving 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 this manual for driv
21. the ignition key past the POSITION LIGHTS position to engage the starter Engage the starter for only 2 3 seconds Dry the spark plug Reinstall the plug or install a new plug Torque to specification See page 96 Tighten the carburetor drain screw Turn the fuel valve on necessary repeat the drying procedure Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not MAINTENANCE 2 a 4 D We D If water has been ingested into the PVT follow the procedure on page 105 for drying out the PVT 99 MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C or higher Above 1800 meters the engine air fuel mixture becomes too rich and the engine loses approximately 3 of its power for each 300 meter increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets and clutch components available from your Polaris dealer 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 PVT or engine damage See your Polaris dealer for more information about jetting the vehicle for condi tions in your area C
22. the key Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 4 Reverse the procedure to unlock the steering A The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gaso line with a minimum pump octane of 87 Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 28 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle High Gear Low Gear Neutral Reverse 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 could cause transmission damage To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear See your dealer if you experience any shifting problems waar Ss Passenger Seat Latch Always make sure the passenger seat is installed and securely latched before operating with a passenge
23. the vehicle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating 26 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 39 cranking the engine with the recoil Handle starter instead of the main key DEDA switch we e 1 Grasp the recoil starter rope Do N handle tightly 2 Pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine A 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 housing and damage components Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 39 for correct choke and throttle settings during start ing Fuel Valve The fuel valve is located under the front storage box cover OFF For vehicle storage and when transporting ON For normal operation ON OFF 27 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 Tip The handlebars may also be locked in the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove
24. with an accurate log of maintenance and ser vices performed DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 130 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 131 INDEX 0 9 4X4 System 30 31 A ACCESSOFICS 0 0 eee eee eee 116 Age Restrictions 5 Air Filter 0 000 90 All Wheel Drive Switch 22 All Wheel Drive System 30 31 B Battery 0 eee eens 106 110 Charging Conventional 109 Charging Sealed 109 110 Fluid Conventional 108 Installation 107 Removals ci64 fac sacra at 107 Storage 0008 108 BOOS ois eect ne snare yr eye Wn seas atten ts 9 Brake Fluid 78 80 Brake Inspections 81 Brake Foot 0 25 Brake Hand 00 25 Brake Parking 26 Brakes sern veces eh ce bees 81 Break In Period 37 Breather Filter 91 Breather Hose 91 Cc Carburetor 000 100 Carburetor Adjustment 100 Carros ado ae Gent itu eects ee ots 59 Cargo Loading 58 Chokes 2 525 ee eee Mae eat 27 Chrome Wheel Care 113 Cleaning and Storage 111 116 Clothing
25. 8 Reinstall the dipstick MAINTENANCE Engine Oil Oil and Filter Change A 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 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 New Sealing Washer 9 Clean the drain plug Reinstall the drain plug with a new sealing washer O 10 Torque to specification See page 66 N Co 68 MAINTENANCE Engine Oil Oil and Filter Change 11 Tip 12 13 14 15 16 17 18 Tip 19 Disconnect the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean the fitting The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank Do not over tighten Maximum torque for the screen fitting is 34 N m Reattach the oil line Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the crankcase Install the new oil filter After the filter conta
26. Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 15 A 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 51 OPERATION Driving Through Water Follow these procedures when driving through water l 2 3 4 52 Check water depth and current before crossing Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles 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 Wet brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal 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 98 Have the vehicle serviced by your dealer promptly A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water A If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to you
27. Do not oper ate the vehicle if this warning appears Serious engine damage could result 9 Mode Indicator 3 4 5 6 7 33 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 Tip The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles or kilometers traveled by the vehicle Trip Meter Mode The trip meter records the miles 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 changes to 0 Tip 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 engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation 34 FEATURES AND CONTROLS 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 diag
28. GL Synthetic 32 oz 948 ml See page 72 Gearcase Lube Demand Drive Demand Drive Plus Fluid 9 oz 265 ml See page 74 Grease fittings 3 pumps maximum every 800 km before long periods of stor age or after pressure washing or submerg ing Front Prop Shaft Yoke 65 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing 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 ture operation A 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 1 9 liters 19 23 N m Synthetic 2W 50 4 Cycle Oil 66 MAINTENANCE 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 6 Reinstall the dipstick completely Dipstick 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range a SS
29. Information Center The rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up 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 shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 4X4 Indicator This indicator illuminates al when the 4X4 switch is 1 on 4X4 3 Engine Hour Display Indicator 4 Service Interval 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 at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 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 display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats
30. LL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris dealer 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 DEALER IS YOUR RESPONSIBILITY 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 person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 129 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners
31. Pantone 426c ca er POLARIS The Way Out Sportsman 500 Touring International 2010 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age F E Pantone 426c Before you operate or ride this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug bedienen oder fahren Antes de operar o conducir este vehiculo lea el Manual del propietario Lire le Manuel d utilisation avant d utiliser ou de conduire ce v hicule Prima di usare o guidare il veicolo leggere il Manuale di istruzioni Lue aina kayttoohjekirja ennen taman ajoneuvon k ytt tai ajamista Antes de utilizar ou andar neste ve culo leia o Manual do propriet rio Innan du hanterar eller k r detta fordon l s Handboken CD CED lt gt QD CD CP Cs PELARIS For your nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9922551 Rev 01 Printed in U S A 100 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW 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 e Snowmobi
32. RTSMAN 500 EFI 2008 2009 2010 80 4 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55_ _DNS5 SPORTSMAN X2 TOURING 550 2010 77 2 ___MN76__ SPORTSMAN 800 2008 2009 2010 83 6 TN85 _ DN85 SPORTSMAN X2 TOURING 850 2010 77 2 __CL76 __ SPORTSMAN 800 6X6 2009 2010 80 1 ZN85_ ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HA6 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY __ RANGER HD 800 4X4 2010 76 5 __VH76__ RANGER RZR 2008 2009 2010 85 8 Authorized Signatory Akotander 4 Feneda Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 125 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warr
33. a surement on each side of the vehicle to obtain the recommended 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 82 MAINTENANCE Handlebar Adjustment The handlebars can be adjusted for rider preference A Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting 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 rear two bolts A gap of up to 3 mm will remain at the rear of the clamp blocks 83 MAINTENANCE 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 Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension Adjuster 84 MAINTENANCE Side Panel Removal l
34. ain while cornering or while ascending or descending hills 58 OPERATION Hauling Cargo Towing Loads Towing is approved OFF ROAD ONLY Towing a trailer on public roads is prohibited See your Polaris dealer about configuring the vehi cle to be certified to tow a trailer on road Do not tow any trailer on a grade steeper than 15 Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The 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 weight capacity of the vehicle A Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can result 17 cm in serious damage to the vehicle and will void your warranty Never install a hitch longer than 17 cm Never install automotive accessories on your Polaris vehicle Always install Polaris approved or equivalent accessories designed for use on the Polaris vehicle 59 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements 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 in
35. an following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Do not operate at full throttle or high speeds for extended periods during the first three hours of 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 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 inspection checklist See page 38 6 Pull only light loads 7 Change the oil and filter at one month PVT Break in Clutches Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period 37 OPERATION Pre Ride Checklist Item Remarks Page Hand brake lever travel Ensure proper operation 81 Foot brake Ensure proper operation 81 Brake fluid Ensure proper level 81 Passenger seat latch Ensure latch is secure 29 Front suspension Inspect lubricate if necessary 65 Rear suspension Inspect lubricate if
36. anty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 126 WARRANTY 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 vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control Warrant
37. arburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Start the engine and allow it to warm up for approximately five minutes Place the transmission in gear Lock the parking brake Aw Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Idle Screw 100 MAINTENANCE Recoil Housing if equipped 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 Remove the drain screw on the bottom of the recoil housing 4 Allow the housing to drain com pletely 5 Reinstall the drain screw Tip Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened SY 101 MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under
38. ations Demand Drive 74 Engine Oil 66 Transmission 72 Foot Brake 0000005 25 Footwell Removal 85 Front Gearcase Fluid 74 75 Fuel Piter o eeerareas ras saarah 28 Fuel Safety 000 16 Fuel Tank Cap 28 Fuel Valve 00 27 28 Fuse Replacement 95 G Gasoline Handling 16 Gear Selector 0005 29 GLOVES ns sche seh ote ANA eae eae d 9 H Handlebar Adjustment 83 Hauling Cargo 58 59 Hazard Warning Switch 22 Headlight Lamp 93 Helmet 0 0 20 0 0 0 0 ce eee 8 High Beam Adjustment 92 High Range Use 41 Horn Switch 08 23 Hub Tightening 87 l Idle RPM Adjustment 100 Immersion 0000 eee 99 Immersion Maintenance 98 Instrument Cluster 32 36 J Jetting Chart 119 K Key Switch 0 21 K Tum 005 50 51 L Light Switch 21 Wit oct sobs monona eet 92 94 Front Turn Signal 94 Headlight Lamp 93 High Beam Adjustment 92 Position Light Lamp 93 Rear Turn Signal 94 Taillight 00 94 Low Range Use 41 Lubrication Guide 65 M Maintenance Chart 61 64 Mitt esa ei
39. can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating this Polaris vehicle Safety Training When you purchased your new Polaris vehicle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Polaris vehicle from 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 under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road Equipment Modifications The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle INTRODUCTION Vehicle Identification Numbers Recor
40. cle handling and could cause an accident e Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner s manual e Use only original equipment size and type when replacing tires e Make sure the wheels are installed properly e Replace tires when the tread depth measures 3 mm or less Refer to the specifications section beginning on page 118 for recom mended tire type size and pressure 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 Tire Tread Depth Always replace tires when 3mm tread depth is worn to 3 mm or less DNS A 87 MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Cast Aluminum Nut Type Nut Torque Lug Nut 122 Nm 2 Piece Flange Nut 37 Nm 88 MAINTENANCE Tires A 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 5 Remove the wheel nuts 6 Remove the wheel Place the whee
41. ct ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery 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 Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Kinked or plugged fuel vent line Possible Rich Fuel Cause Fuel is very high octane Inspect and replace if equipped Solution Replace with lower octane fuel Overuse of choke Inspect clean and or replace spark plugs Stopping starting without adequate warm up Allow engine to warm up before opera
42. cts the crankcase surface turn it 1 2 turn by hand Lubricate the filter o ring Check to make sure the o ring is in good condition y Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to specification See page 66 69 MAINTENANCE Engine Oil Oil and Filter Change 20 Remove the dipstick 21 Add 1 9 liters of recommended Y oil If the sump is not drained add about 1 6 liters initially 22 Reinstall the dipstick R ARN SH 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 Range Add Oil Safe 70 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 l 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 Start the engine Allow it to idle for 10 20 seconds MAINTENANCE
43. d 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 The ignition switch must be replaced if all keys are lost Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Equipment Modifications We strongly recommend that consumers do not install on a Polaris vehi cle 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 equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the
44. de 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 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 button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 36 OPERATION Break In Period The break in period for your new Polaris vehicle 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 performance of your vehicle more th
45. ding gear See page 8 Perform the pre ride inspection See page 38 Place the transmission in PARK Mount the vehicle from the left side Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up Apply the brakes Shift the transmission into gear Check your surroundings and determine your path of travel Release the brakes Slowly squeeze the throttle lever toward the handlebar to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle l Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn 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 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 rest Use the same leaning technique for turning in reverse Never turn quickly when carrying a passenger or cargo Practice making turns at slow speeds before attempting to turn at faster speeds 43 OPERATION Driving with a Passenger A 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 o
46. ditional power while operating in reverse press the override switch before opening the throttle 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 A Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open 20 FEATURES AND CONTROLS Switches Main Key Switch ge End all electrical power to the vehicle D LIGHTS ON position turns the headlights on Start the engine The headlights are not on in this position D dE After starting the engine release the key switch to the POSITION LIGHTS ON position A 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 Engine The engine will not start or run when Stop Switch the switch is in the OFF position OFF O RUN Light Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position D High Beam 4 Low Beam 21 FEATURES AND CONTROLS Switches 4X4 Switch Cs 4X4 Switch Use the 4X4 switch to engage 4X4 or 2X4 See page 30 Hazard Warning Switch Haza
47. e lever The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 24 FEATURES AND CONTROLS 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 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 A Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes 25 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 Torelease the parking brake lock squeeze and release the brake lever A Operating
48. e 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 Collar Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully remove the collar and socket gt E Headlamp 6 Remove the lamp Apply dielectric grease to the socket and install a new lamp Socket 7 Reverse all steps to reassemble the Vong headlight ail HRT 93 MAINTENANCE Lights Taillight Lamp Replacement l 2 Place the transmission in PARK Rotate the taillight socket counterclockwise to remove it Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order Front Turn Signal Lamp Replacement l Place the transmission in PARK Remove the lens attachment screw Rotate the lamp to remove it Install the new lamp Reinstall the lens Rear Turn Signal Lamp Replacement 1 2 94 Place the transmission in PARK Rotate the turn signal socket counterclockwise to remove it Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order MAINTENANCE Fuse Replacement If the engine stops
49. e self adjusting Brake Inspections Perform the following checks to keep the brake 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 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 the security and surface condition of the disc 81 MAINTENANCE Toe Alignment A Do not attempt to adjust alignment All steering adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire 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 ve Stand String 2 gt 1 gt yi Vy Ps l l l l A l l l O The rear measurement should be 2 3 mm more than the front me
50. e the vehicle to your dealer for service as soon as possible 105 MAINTENANCE Battery AWARNING 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 AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce 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 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 necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with ta
51. ee page 28 A Handling Gasoline Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e 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 stored Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Turn the fuel valve off whenever the vehicle is stored or parked A 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 safety contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com 16 SAFETY Safety Decals and Locations 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 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 or ride this vehicle read the owner s manual
52. ement part 77 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 120 for the part numbers of Polaris products A 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 ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to d
53. endations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Demand Drive Demand Drive Plus Fluid 265 ml 11 14 N m 15 N m Unit Use the recommended fluid Use of other fluids may result in improper operation of components See page 120 for the part numbers of Polaris products Maintain 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 Add the recommended demand drive fluid as needed 5 Reinstall the fill plug Torque to specification 74 MAINTENANCE 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 Reinstall the drain plug Torque on to specification See page 74 Add the recommended fluid 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 75 MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair replace the coolant with a fresh mixture of antifreeze and water Drain the cooling system every two years Add fresh coolant Polaris recommends the use of Polaris Premium 60 40 anti freeze cool an
54. engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 111 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 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 fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 68 Air Filter Air Box l a and clean or replace the pre cleaner and air filter See page 2 Clean the air box 3 Clean or replace the breather filter See page 91 4 Drain the sediment tube Recoil Housing if equipped Drain the recoil housing See page 101 114 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 61 e Demand drive unit front gearcase e Rear gearcase if equipped Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated
55. erating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack e CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises 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 e 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 See specifications beginning on page 118 e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle e USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn e TOWING is approved OFF ROAD ONLY Towing a trailer on public roads is prohibited e TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terr
56. ers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills 45 OPERATION Driving Uphill 15 Maximum Whenever traveling uphill follow these precautions Avoid steep hills 15 maximum Avoid hills with slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Drive straight uphill Proceed at a steady rate of speed to avoid stalling pol Va ee eer Be alert Be prepared to take emergency action This may include dismounting quickly o9 Never open the throttle suddenly or make sudden gear changes 9 Never go over the top of a hill at high speed 46 OPERATION Driving Uphill Ifall 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 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 around See page 50 A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 15 A Always follow the
57. es avs Saw Soy ee eee ad 9 Clutching 204 119 Cold Weather Operation 41 Coolant Bottle 76 Coolant Radiator 77 Cooling System 76 77 Corrosion Removal Chrome 113 132 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 Sidehill 48 Driving on Slippery Surfaces 54 Driving Over Obstacles 55 Driving Procedures 42 Driving Through Water 52 53 Driving Uphill 46 47 Driving with a Passenger 44 45 E Electromagnetic Interference 60 Electronic Throttle Control 24 Engaging 4X4 0 2 eee 31 Engine Break In 37 Engine Fogging 115 Engine Idle RPM Adjustment 100 Engine Oil 66 71 Equipment Modifications 5 7 Exhaust Emission Control System 60 Eye Protection 9 F Fluid Brakes semoni had onda 78 80 Demand Drive 74 75 Engine Oil 66 71 Front Gearcase 74 75 Transmission 72 73 Fluid Change Demand Drive 75 Engine Oil 68 71 Transmission 73 Fluid Level Demand Drive 74 Engine Oil 67 Transmission 72 F Fluid Recommend
58. ing See page 107 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 107 Make sure the positive terminal is toward the 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 battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage A An overheated battery 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 109 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 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until
59. ing downhill and for braking on hills Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 49 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 Stop the vehicle Keep your weight uphill Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off 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 uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking brake 7 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward pee a 50 OPERATION Turning Around on a Hill K Turn 8 Lock the hydraulic parking brake 9 Remount from the uphill side Keep your weight uphill A passenger should not remount until the vehicle returns to level ground 10 Apply the foot brake 11 With the transmission still in forward start 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 vehicle is on level ground A
60. io Front 3 82 1 Tires Pressure Front 25x8 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 wheel Headlight 2 Hi Lo beam on bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching EBS Models Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 10 WH Blue Green Yellow EBS Feet 0 6000 PN 5630710 PN 7041157 PN 3234451 PN 3234356 1800 3700 10 RH Blue Green Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 3234451 PN 3234356 EBS models require no helix spring adjustment Jetting Chart AMBIENT TEMPERATURE 6000 12000 ee Below 40 F 40 F and ab elow a 40 F and above Meters Feat Below 5 C 5 C and above 0 1800 0 6000 760 155 1800 3700 1525 1475 119 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil 95 I 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil 3 8 I Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant 95
61. iring end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 96 MAINTENANCE Spark Plugs Spark Plug Removal 1 Remove the left side panel See page 85 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 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 97 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 A 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 Turn the fuel valve off 3 Check the air box If water is present dry the air box and replace the filter with a new filter 4 Remove the spark plug 98 Vehicle Immersion 5 6 10 11 Attempt to start the engine If 12 13 Loosen the carburetor drain screw Turn
62. ity 1995 Ibs 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 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 7 qts 2 5 1 Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EHSOPLE Displacement 499 cc Bore x Stroke 92mm x 75mm Alternator Output 350 w Compression Ratio 10 2 1 Carburetor 40mm Mikuni Pilot Jet 40 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 30 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 Based on EU Directive 76 432 EC 118 Driving System Type SPECIFICATIONS SPORTSMAN 500 Touring International Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 8 75 22 cm travel Transmission Automatic EBS Engine Braking System w E Z Shift H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction High 10 57 1 Drive Rat
63. k the rear wheels on the downhill side Turn the fuel valve off OPERATION Driving in Reverse Follow these precautions when operating in reverse l DN es S Always check for obstacles or people behind the vehicle before backing Be aware that a passenger can obstruct your view Avoid backing downhill Drive slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override switch unless additional power is required for vehicle movement Use with caution A 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 A Always follow the procedures outlined in this manual for driving in reverse 57 OPERATION Hauling Cargo A 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 e Read and understand the load distribution warnings listed on the vehicle warning labels e Never exceed the stated load capacity for this vehicle e Never carry cargo on the rear rack when operating the vehicle in the 2 up mode with a passenger e REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill e When op
64. l on the hub 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 89 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 61 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the seat Release the air box cover clips 5 Remove the air box cover 6 Loosen the hose Pre Filter clamp E Remove the filter hj Main Filter 8 Remove the pre filter f from the filter Ad VA Q 9 Wash the pre filter in soapy water Rinse and air dry 10 Replace the filter if needed 11 Reverse the steps to reinstall all components 90 MAINTENANCE Breather Filter Hose The breather filter is on the hose between the engine and air box 1 Remove the left side panel See page 85 2 Remove the hose clamps from the filter and pull the filter out of the hoses 3 Inspect the filter for debris Blow N gently through the filter in the ag direction of the arrow to check 5 va EN for clogging Replace a damaged Breather Filter or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clamps Tip The filter is effective with the arrow pointing in either direction A Operation of your vehic
65. le without a breather filter can cause engine damage 91 MAINTENANCE 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 Tip 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 upward or downward or to the left or right 92 MAINTENANCE Lights A 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 Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK Position Light 2 Open the front rack cover 3 Remove the plug at th
66. les e All terrain vehicles ATVs e RANGER utility vehicles e Victory 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 more information about Polaris visit us online at www polarisindustries com CY POLARIS The Way Out POLARIS THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality 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 expressly prohibited Printed in U S A 2010 SPORTSMAN 500 Touring International Owner s Manual P N 9922551 2 TABLE OF CONTENTS Introduction oicci cian tei ore teed ee
67. n this 2 up vehicle Never carry more than one passenger on this 2 up vehicle 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 an approved helmet with a rigid chin guard See page 8 3 Perform the pre ride inspection See page 38 4 Always make sure the passenger seat is installed and securely latched before operating with a passenger 5 Place the transmission in PARK 44 OPERATION Driving with a Passenger 6 T Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side A Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator 8 9 10 Drive slowly Control may be more difficult with a passenger on board Allow more time and distance for braking Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle Do not cross a hillside with a passenger on board See page 48 11 Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 12 Make sure the passenger understands the importance of active riding When hill climbing or performing maneuv
68. n 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 to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 111 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Radiator Transmission seals e Brakes e Cab and body panels e Labels and decals e Electrical components and wiring If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge 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 Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of
69. nostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on 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 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 This screen is for informa tional purposes only Please see 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 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory To enable or disable the service interval 1 Enter the diagnostic mo
70. occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads 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 However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 104 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Dry it out before operating l 2 Tip Position the vehicle on a level surface Place the transmission in PARK Remove the drain plug Allow the water to drain completely Rein stall the drain plug Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Tak
71. or will not start or P if you experience other electrical fail ures a fuse may need replacement Tip Spare fuses are provided in a compart l 2 3 ment on the top of the access door Open the front box cover Open the access door Remove the suspect fuse from the fuse panel Install a new fuse with the same amperage Secure the access door Secure the box cover 95 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 12 15 N m Previously Installed Spark Plug 23 27 N m Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color Normal Spark Plug The normal insulator tip is tan or brown 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 carburetion adjust ments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the f
72. p water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 106 MAINTENANCE Battery Battery Removal Place the transmission in PARK Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last SOY oe eo Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 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 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 A Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals with
73. r Test the seat latch by attempting to pull the seat upward If the latch is not working properly do not allow a passenger to ride the vehicle See your Polaris dealer for service To remove the seat pull the latch loop at the rear of the seat Pull the seat upward to remove it from the vehicle To reinstall the seat make sure the rubber feet at the base of the seat are positioned in the rear rack Press down firmly on the seat pad until the latch clicks 29 FEATURES AND CONTROLS All Wheel Drive 4X4 System 4X4 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 Tip The override switch allows activation of 4X4 in reverse if the 4X4 switch is on See page 20 2X4 When the switch is on 2X4 the vehicle is in two wheel drive at all times 30 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 If the switch is turned off while the
74. r dealer before starting the engine 53 OPERATION 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 Be alert Watch the trail Avoid quick sharp turns DN le ee 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 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning Engage 4X4 when the wheels have traction 54 OPERATION Driving Over Obstacles Always check for obstacles before operating in a new area Be alert Watch the terrain Use extra caution Never operate over large obstacles Avoid hazards such as logs rocks and low branches Ae a Always have a passenger dismount before operating over an obsta cle A Always follow the procedures outlined in this manual for operating over obstacles 55 OPERATION Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions l 2 3 4 56 Stop the engine Place the transmission in PARK Always bloc
75. r for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your vehicle Always install Polaris approved or equivalent accessories designed for use on the Polaris vehicle 116 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle l 2 3 Stop the engine ae H Place the transmission in PARK y Secure the fuel cap oil cap and N y seat Turn the fuel valve off Remove the key to prevent loss during transporting 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 pockets 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 the Polaris vehicle 117 SPECIFICATIONS SPORTSMAN 500 Touring International Maximum Weight Capacity 568 Ibs 258 kg includes operator passenger cargo accessories Dry Weight 791 Ibs 359 kg Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Rack Capacity 180 Ibs 82 kg Receiver Hitch Tongue Capacity 120 Ibs 54 4 kg Rear rack capacity and tongue weight not to exceed 180 Ibs 82 kg Hitch Towing Rating 1225 Ibs 555 7 kg Unbraked Trailer Towing Capac
76. rd Warning Switch A Push the hazard warning switch to cause all turn signal lights to flash an emergency or other situation requiring caution Indicators 22 FEATURES AND CONTROLS Switches Turn Signal Switch lt 1 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 Turn Signal Horn Switch Switch Horn Switch box Press the horn switch to sound the horn 23 FEATURES AND CONTROLS 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 A 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 Check occasionally during operation Do not 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 Always check and adjust the mirrors before driving the vehicle Electronic Throttle Control ETC ETC causes the engine to Electronic Throttle Control stop if the throttle cable sticks in an open position when the operator releases the throttl
77. re operating the vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified 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 and all product labels and have completed a certified safety training course A 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 vehicle Never carry more than one passenger on this 2 up vehicle 10 SAFETY Rider Safety 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 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 other stunts Always inspect your vehicle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 38 11 SAFETY Rider Safety Keep both hands on the handlebars Keep both feet on the footrests A passenger should always be seated in the passenger seat with bo
78. rop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 78 MAINTENANCE Brake Fluid Hand Brake Indicator The master cylinder is Master Window 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 ona 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 79 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 Open the front box cover Open the access door View the fluid level in the reservoir Aw 5 Remove the cap and add the recommended fluid as needed NOTICE Always use the recommended brake fluid 6 Maintain the fluid level between the minimum and maximum marks Do not overfill Brake Fluid Reservoir Maximum Minimum a 80 MAINTENANCE 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 ar
79. rt bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Climbing over large objects from a stopped position 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 Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Dry out the PVT See page 105 Inspect clutch seals for damage if repeated leaking occurs See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 48 km h for 1 6 km Operate 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 37 121 TROUBLESHOOTING Engine Does Not Rotate Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all
80. s ede eee de keke s 24 Mode Switch 0 20 Modifications 5 7 N Noise Emission Control System 60 0 Oil Engine 66 71 Transmission 72 73 Oil Change Engine 68 71 Transmission 73 Oil Level Engines sod neat tdoks b14008 67 Transmission 72 Oil Pump Priming 71 Oil Recommendations Engine Oil 66 Transmission 72 Override Switch 20 P Parking Brake 26 Parking on an Incline 56 Passenger Seat 29 Periodic Maintenance Chart 61 64 133 INDEX P Polaris Product List 120 Polishing the Vehicle 112 Position Light Lamp 93 Pre Ride Checklist 38 PVT Break In 37 PVT Operation 41 PVT System 104 105 R Recoil Housing 101 Recoil Starter 27 Reverse Operation 57 Reverse Override Switch 20 Rider Information Center 33 36 Rider Safety 10 16 Riding Gears ct fess ues as 8 9 S Safety Decals 17 19 Age 16 Alert 17 General Alert 17 Hill Operation Alert 17 Rack Warning Front and Rear 19 Reverse Override Alert 18 Tire Pressure Load Alert 18 Safety Training 5 Severe Us
81. stalled and functional when the vehicle is operated Exhaust 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 maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 60 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 32 Record maintenance and service in the Maintenance Log beginning on page 130 Service and adjustments are important 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 e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation e Extended idle e
82. t ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 123 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace if equipped Overuse of choke Inspect clean and or replace spark plugs Water is present in fuel Replace with fresh recommended fuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark 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 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 engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris
83. t 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 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 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 needed 1 Check the coolant level when the fluid is cool 2 Remove the left side panel See page 85 3 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool View the coolant level 5 Add coolant as needed Reinstall the side panel 76 MAINTENANCE Cooling System Radiator Coolant A Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot l 2 NOTICE Use of a non standard Open the front box cover Open the access door Remove the radiator pressure cap If coolant is not visible slowly add coolant through the radiator filler neck Reinstall the pressure cap Secure the access door and box cover pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replac
84. t readily start intermittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 13 If the engine slows or stops position the choke knob half way in to 40 allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in OPERATION Cold Weather Operation Internal engine condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level fre quently A rising oil level could indicate condensation in the bottom of the oil tank which can lead to engine 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 in rough or rugged terrain Low Operating at speeds greater than 11 km h High 41 OPERATION Driving Procedures 42 Wear protective ri
85. th feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Always 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 turning See page 43 Never turn sharply at excessive speeds which can lead to vehicle overturn A If the vehicle 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 12 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving on hills See page 46 Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 15 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 vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a
86. the vehicle while 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 arrestor clean out plug from the bottom of the muffler 4 Start the engine 5 Quickly squeeze and release the throttle lever several times to purge car bon from the system 102 MAINTENANCE Spark Arrestor 6 10 11 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves Lightly tap on the exhaust pipe with a rubber mallet while repeat ing step 5 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 Place the transmission in PARK Repeat steps 5 to 7 until no more particles are expelled Stop the engine Allow the arrestor to cool Reinstall the arrestor plug and remove the exhaust outlet cover or plug 103 MAINTENANCE PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may
87. vehicle SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury 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 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 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear 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 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 jersey with shoulder pads provide the best protection SAFETY Rider Safety A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels befo
88. wees 4 Safety 6 4 4 c edie ee SSS e Reet ost eos 7 Features and Controls 20 05 20 Operation ce 2 23 eed rele er ee eid 37 Emission Control Systems 60 Maintenance 000e eee eee eee 61 SpecificationS 00 cece eee eee 118 Polaris Products 0000eeeees 120 Troubleshooting 0000ee eee eee 121 Declaration of Conformity 125 Warranty iia dota ese G eae eae eae es 126 Maintenance Log 0000eeees 130 INDOX eve eek eee tee eae ae 132 INTRODUCTION 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 A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not 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 Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death This Polaris vehicle is not a toy and
89. which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 112 MAINTENANCE 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 Tip Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent 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 product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 113 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the
90. will prevent the engine from starting if the transmission is in gear and the brake is not engaged Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled If the engine is cold pull the choke knob out until it stops The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed completely in The choke can be adjusted gradu ally depending on how much choke is needed for starting Be sure the choke is off during opera tion as excess fuel washing into the engine oil will increase wear on engine components If the knob doesn t stay where positioned increase the ten Tension sion by rotating the tension Adjusting Nut adjusting nut clockwise 39 OPERATION Starting the Engine 8 10 If the engine does not start release the 11 Move the engine stop switch to RUN Do not press the throttle while starting the engine Turn the ignition key past the POSITION LIGHTS ON position to engage the starter Activate the starter for a maxi mum of five seconds releasing the key when the engine starts starter and wait five seconds Repeat steps 9 and 10 until the engine starts A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 12 If a warm engine has cooled to a point where it does no
91. y does not apply 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 e Wheels and tires e Finished and unfinished surfaces e Suspension components e Carburetor Throttle body components e Brake components Engine components Seat components Drive belts e Clutches and components e Hydraulic components Steering components Circuit breakers Fuses e Batteries e Electronic components e Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim e Spark Plugs e Lubricants such as oil grease etc e Filters e Batteries unless defective e Fuel Cosmetic damage repair e Sealants e Coolants e Hotel fees e Meals Towing charges e Shipping handling fees e Mileage e Product pick up delivery e Rentals Loss of product use e Loss of vacation personal time 127 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error

Polaris 9922551 Offroad Vehicle User Manual

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