Polaris 9921309 - Manual

5 KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable informa- tion about all aspects of your vehicle, including safe operating pr...

6 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the de...

7 SAFETY Safety Decals and Locations Tire Pressure/Load Warning WARNINGIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) CENTER 5 (34.5) REAR 5 (34.5)MAXIMUM WEIGHT CAPACITY 1090 LBS. (494 kg) INCLUDES WEIGH...

8 SAFETY Safety Decals and Locations Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER operate this ATV if you are under age 16. Container/No Passenger Warning WARNINGRemove flammable containers from box before refueling.WAR...

9 SAFETY Safety Decals and Locations All Wheel Drive Switch Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. Hitch Capacity Label TRAILER MAX WEIGHT:1500 LBS. (682 KG) ON LEVEL GROUND850 LBS. (386 KG) UP T...

10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established...

11 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 mark...

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.A Polaris ATV is not a toy and can be hazardous to operate....

13 SAFETY Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV...

14 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this man...

15 SAFETY Operator Safety • Read this manual and all labels carefully, and follow the operating procedures described. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse ...

17 SAFETY Operator Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. ...

18 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifica...

34 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on. Th...

35 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch to the center (OFF) position to stop the engine quickly. The stop switch provides the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. The engine will not start or run when the switc...

36 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are controlled by pressing the throttle lever. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is design...

37 FEATURES AND CONTROLS Brake Systems The braking system is controlled by the two brake levers located on the handlebars. Service Brake Lever The service brake lever is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this lever for normal braking.App...

38 FEATURES AND CONTROLS Brake Systems Master Cylinders/Brake Fluid The master cylinders are located on the left and right handlebars. Check fluid levels before each use of the ATV. The fluid level can be seen through an indicator window on the top of the master cylin- der. This eye will appear dark...

39 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Squeeze and release the brake lever two or three times, then squeeze and hold. 2. Push the parking brake lock forward to engage the lock. 3. Release the brake lever.4. To release the parking brake lock, squeeze and release the brake...

40 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Valve The fuel valve is located on the left side panel. It has three positions:OFF:...

41 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: Reverse To change gears, stop the vehi- cle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gea...

42 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter. The recoil starter is located on the right side of the vehicle. Follow the starting procedures on page 53, crank- ing the engine with the recoil starter instead of the main key switch.1. G...

43 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is off, the vehi- cle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the front wheels will automatically engage any time the rear w...

44 FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging Wheel Hubs The hubs normally disengage when operating in reverse. However, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, one front hub is engaged. If both hubs are engaged, steering effort incre...

45 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures dis- tance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that li...

46 FEATURES AND CONTROLS Instrument Cluster Rider 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. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the inst...

47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes The rider information center has 4 standard modes. The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle throu...

48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the diagn...

50 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline.• 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 ne...

51 OPERATION Break-In Period The break-in period for your new Polaris ATV 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 is as important as following the proce- dures for a proper break-in. Careful treatment of a n...

52 OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 37 85 Brake fl...

53 OPERATION Starting the Engine 1. Position the vehicle on a level surface.2. Place the transmission in neutral.3. Lock the parking brake. NOTE: The starter interlock will prevent the engine from starting if the trans- mission is in gear and the brake is not engaged. 4. Turn the fuel valve on.5. Si...

55 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety deca...

56 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake.3. Dismount the vehicle.4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution. 5....

57 OPERATION Hauling Cargo Load Distribution 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 55. 2. Always load the cargo box with the load as far forward as possible.3. Always operate the vehicle with extreme caution whenever ha...

58 OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10.2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. See page 53.4. Shift the transmission into gear.5. Check your surroundings and dete...

59 OPERATION Driving Safely Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives all rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip tractio...

60 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions:1. Slow down when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high...

61 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Drive straight uphill.2. Avoid steep hills (15 ° maximum). 3. Keep both feet on the footrests.4. Shift your weight uphill.5. Proceed at a steady rate of speed and throttle opening.6. Remain alert and be...

63 OPERATION Driving Safely Driving Downhill When driving downhill, follow these precautions:1. Shift your weight uphill.2. Drive straight downhill.3. Slow down.4. Apply the brakes slightly to gradually slow the vehicle. NOTE: Before operating your ATV, learn how to use the auxiliary brake for emerg...

64 OPERATION Driving Safely 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. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3. D...

65 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these procedures when operat- ing through water:1. Determine water depths and current before crossing. 2. Choose a crossing where bot...

66 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. ...

67 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly.4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the...

68 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Place the transmission in gear.3. Lock the parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.

69 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205.158) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris veh...

70 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust and replace part...

71 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dea...

74 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Items not listed in the chart should be lubricated at the general lubrication interval. NOTE: The a-arms and lower control arms are lubricat...

76 MAINTENANCE Engine Oil Oil Recommendations 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 recommendat...

77 MAINTENANCE Engine Oil Oil Level The oil dipstick is on the left side of the ATV.1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick securely. NOTE: ...

78 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Always change the oil filter whenever changing oil.1. Position the vehicle on a level surface.2. Start the engine. Allow it to idle for two to three...

79 MAINTENANCE Oil and Filter Change 8. Reinstall the screen fitting and rotate the fitting clockwise a mini- mum of 2 1/2 turns into the tank threads. Continue to rotate the fit- ting until the nipple of the fitting aligns with the mark on the tank. NOTE: Do not over-tighten. Maximum torque for the...

80 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank...

81 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant....

82 MAINTENANCE Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads.We recommend the use of Polaris Premium ATV Angle Drive Fluid. See page 1...

83 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.As coolant operating temperature increases, the expanding (...

84 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.Replace the coolant any time the cooling system has been drai...

85 MAINTENANCE Brakes Rear Brake The transmission brake is a hydrau- lic disc brake. This brake is acti- vated by the left brake lever, which also activates the front brakes. The transmission brake system is self- adjusting.Periodically check the brake pads for wear. Replace brake pads when they are...

86 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (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 betwe...

87 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.2. Grasp the rear of the side panel ne...

88 MAINTENANCE Tires Refer to the specifications section beginning on page 124 for recom- mended tire type, size and pressure. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. Stop the engine.2. Place the transmission in gear.3. Lock the par...

89 MAINTENANCE Tires Wheel Installation 1. Place the transmission in gear.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and fin- ger-tighten them. Make sure th...

90 MAINTENANCE Air Filter Always inspect and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.1. Remove the seat.2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric ty...

91 MAINTENANCE Breather Filter/Hose Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.1. Remove the hose clamps from the filter and pull the filter out of the hoses. NOTE: It's not necessary to remove the lower hose from t...

92 MAINTENANCE Lights When servicing a halogen lamp, don't 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. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove ...

93 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Lock the parking brake. 2. Measure ...

94 MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod.3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the h...

95 MAINTENANCE Lights Taillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp.3. Apply dielectric grease to the socket and install the new lamp. 4. Test the light for proper opera- tio...

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 124 for the recom- mended spark plug type and gap for your vehicle. Always torque spark plugs to specification. Spark Plug Inspection Spark plug condition is indicative of engine operation. Ch...

97 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip shoul...

98 MAINTENANCE Vehicle Immersion 1. If it's impossible to take your ATV to a dealer before starting it, fol- low the steps outlined below. 2. Move the ATV to dry land or at the very least, to water below the footrests. 3. Check the air box. If water is present, dry the air box and replace the filter...

99 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.1. Remove the arrestor clean- out plug from the bottom of the muffler. 2. Place the transmission in neutral. 3. Start the engine.4. Quickly squeeze and release the throttl...

100 MAINTENANCE PVT System WARNING 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 occur at a high speed. The PVT system has been precision balanced. Any...

101 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to th...

102 MAINTENANCE PVT System When To Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing.1. Remove the drain plug. Allow the water to drain completely. Rein- stall the...

103 MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Batte...

104 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap.2. Remove the battery cover.3. On conventional batteries, remove the battery vent tube.4. Disconnect the black (negative) battery cable first.5. Disconnect the red (positive) battery cable last.6. Lift the battery out ...

105 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 107 before installing the battery.1. Ensure that the batter...

106 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...

107 MAINTENANCE Battery 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...

108 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

109 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. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Us...

110 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: • Wheel bearings• R...

111 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 109. Fog the Engine 1. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove the spark plug. Rotate the piston t...

112 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 70.• Front demand drive unit (front gearcase)• Rear gearcase (if equipped)• Transmission• Brake fluid (change every two years and ...

113 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 70. Engine Anti-Freeze Test engine coolant strength and change if necessary. Replace coolant every two ...

114 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in gear. 3. Lock the parking brake.4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable ...

115 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. NOTE: Be sure the handlebars do not contac...

116 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar.1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut.4. Rotate th...

117 ADJUSTMENTS Front Drive Chain Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain. Then pull up and down on the chain. At this point the chain should have 3/16"-3/8" (5-9 mm) deflection. If the chain needs adjust- ment, ...

118 ADJUSTMENTS Rear Axle Drive Chain To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/6"-3/8" (6-9 mm) at the tightest point in...

119 ADJUSTMENTS Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine ...

120 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range or turn around using the K-turn (see page 64). Driving at low RPM or ground speed (3-7 MPH) Drive at ...

121 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possib...

122 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

123 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating 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 Overuse of choke Inspect, clean and/or replace spark plugs Water is ...

124 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 6X6 Maximum Weight Capacity 1090 lbs. (494 kg) (includes operator, cargo, accessories) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.25 qts. (2 l) Transmission Oil Capacity 32 oz. (948 ml) Front...

125 SPECIFICATIONS Clutching Chart Jetting Chart Sportsman 500 6X6 Transmission Automatic PVT (H/L/N/R) Gear Reduction, Low 6.69:1 Gear Reduction, Reverse 5.17:1 Gear Reduction, Forward 3.34:1 Drive Ratio, Front 2:1 Drive Ratio, Final 12:38 80P Tires/Pressure, Front Polaris PXT 25x8-12 / 5 psi Tires...

126 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...

127 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for fai...

128 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 ...

129 WARRANTY ALL 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 SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some state...

130 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...

131 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...

132 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2...

133 WARRANTY California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2006 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with the applicable regulations of the C...

134 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts.When the LSI engine...

135 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty mainte- nance or repairs of emi...

137 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser-vices performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

140 INDEX A Age Restrictions. . . . . . . . . . . . . . . . 12 Air Box Drain . . . . . . . . . . . . . . . . . 90 Air Filter . . . . . . . . . . . . . . . . . . . . . 90 All Wheel Drive System . . . . . . . . . 43 AWD Switch . . . . . . . . . . . . . . . . . . 43 AWD System . . . . . . . . . . . . ....

141 INDEX I Idle RPM Adjustment . . . . . . . . . . . 119 Immersion . . . . . . . . . . . . . . . . . . . . . 98 Instrument Cluster. . . . . . . . . . . . 45-49 J Jetting Chart . . . . . . . . . . . . . . . . . . 125 K Key Switch . . . . . . . . . . . . . . . . . . . . 35 K-Turn . . . . . . . . . . ...