Polaris 9922551 - Manual

5 INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.Read and understand ...

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

7 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 operatin...

8 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 ...

9 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 marki...

10 SAFETY Rider Safety Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor...

16 SAFETY Rider Safety 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. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental s...

17 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...

18 SAFETY Safety Decals and Locations 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. Reverse Override ...

19 SAFETY Safety Decals and Locations Rack Warning, Front and Rear WARNINGWARNING - DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) Clutch Cover Aler...

20 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32.To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse sp...

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

22 FEATURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to engage 4X4 or 2X4. See page 30. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution. 4X4 ...

23 FEATURES AND CONTROLS Switches Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal. Horn Switch Press the horn switch...

24 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. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever stic...

26 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK.2. Squeeze the brake lever toward the handlebar. 3. Push the parking brake lock forward to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake ...

27 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 starter instead of the main key switch.1. Grasp the recoil starter rope handle tightly. 2. Pull...

28 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 the key...

29 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: ParkWhenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when ...

31 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...

32 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 approxim...

33 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.If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument ...

34 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...

35 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 diagnostic mode.T...

36 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,...

37 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 than following the procedures...

38 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, lu...

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

40 OPERATION Starting the Engine 8. Move the engine stop switch to RUN. Do not press the throttle while starting the engine. 9. 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 st...

41 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 condens...

42 OPERATION Driving Procedures 1. Wear protective riding gear. See page 8.2. Perform the pre-ride inspection. See page 38.3. Place the transmission in PARK.4. Mount the vehicle from the left side.5. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 6. Start the engine...

43 OPERATION Turning the Vehicle 1. Before turning, activate a turn sig- nal to alert others of your inten- tions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn whil...

44 OPERATION Driving with a Passenger Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle.Never carry more than one passenger on this 2-up vehicle. 1. Make sure the passenger is at least 12 years of ag...

46 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions:1. Avoid steep hills (15 ° maximum). 2. Avoid hills with slippery or loose surfaces.3. Keep both feet on the footrests.4. Shift body weight uphill.5. Drive straight uphill.6. Proceed at a steady rate of speed to avoid st...

47 OPERATION Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually.2. When fully stopped, lock the hydraulic parking brake.3. A...

48 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:1. Slow down.2. Avoid hills with slippery or loose surfaces.3. Avoid crossing the sides of steep hills.4. Do not cross a hillside with a...

49 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....

50 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. 1. Stop the vehicle. Keep your weight uphill.2. Lock the hydraulic parking brake.3. Leave the transmission in forward gear. Turn the engine off.4. A...

51 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 engin...

52 OPERATION Driving Through Water Follow these procedures when driving through water:1. Check water depth and current before crossing.2. Choose a crossing where both banks have gradual inclines.3. Drive slowly. Avoid rocks and obstacles.4. Avoid operating in water deeper than the bottom of the foot...

53 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. Always follow the procedures outlined in this manual for driving through...

54 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. 3. Be alert. 4. Watch the trail. 5. Avoid...

55 OPERATION Driving Over Obstacles 1. Always check for obstacles before operating in a new area.2. Be alert. Watch the terrain. Use extra caution.3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches.5. Always have a passenger dismount before operating over an...

56 OPERATION Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precau- tions:1. Stop the engine.2. Place the transmission in PARK.3. Always block the rear wheels on the downhill side. 4. Turn the fuel valve off.

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

58 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.• Read and understand the load distribution warnings listed on the vehicle warni...

59 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...

60 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 operatio...

61 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 m...

62 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a Q could result in comp...

65 MAINTENANCE 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. Tip: The a-arms and upper control arms are lubricated at the f...

66 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 u...

67 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. 7. Remove the dip...

68 MAINTENANCE Engine Oil Oil and Filter Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Clean the area around...

70 MAINTENANCE Engine Oil Oil and Filter Change 20. Remove the dipstick.21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 71. 25. Stop t...

71 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the ven...

72 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 Transmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmis...

73 MAINTENANCE Transmission Oil Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. Torque to specification. ...

74 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations 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...

75 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 to specificat...

76 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...

77 MAINTENANCE Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover.2. Open the access door. 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the ...

78 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 m...

79 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through t...

80 MAINTENANCE Brake Fluid Foot Brake The foot brake fluid reservoir is located under the front box. The brake fluid reservoir cap is black.1. Position the vehicle on a level surface. 2. Open the front box cover.3. Open the access door.4. View the fluid level in the reservoir. 5. Remove the cap and ...

81 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 are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Che...

82 MAINTENANCE Toe Alignment 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 sur...

83 MAINTENANCE Handlebar Adjustment The handlebars can be adjusted for rider preference. 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 p...

84 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 eith...

85 MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. 5. When reinstalling side panels, align the f...

86 MAINTENANCE 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...

87 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.• Maintain proper tire pressure as described on the label on your vehicle and in the specifications sectio...

88 MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service. Nut Type Nut Torque Lug Nut 122 Nm 2-Piece Flange Nut 37 Nm Cast Aluminum Steel 122 Nm 37 Nm

89 MAINTENANCE Tires Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest fr...

90 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.4. Release the air box cover clips. 5. ...

91 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 gently through the filter in the di...

92 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 th...

93 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lam...

94 MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp.4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation.6. Reinstall all components in re...

95 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical fail- ures, a fuse may need replacement. Tip: Spare fuses are provided in a compart- ment on the top of the access door. 1. Open the front box cover.2. Open the access door.3. Remove the susp...

96 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. Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the...

97 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 plu...

98 MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro- cedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspec...

100 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 it...

104 MAINTENANCE PVT System 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 modific...

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

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

107 MAINTENANCE Battery Battery Removal 1. Place the transmission in PARK.2. Disconnect the battery hold-down strap.3. Remove the battery cover (if equipped).4. On conventional batteries, remove the battery vent tube.5. Disconnect the black (negative) battery cable first.6. Disconnect the red (posit...

108 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...

109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 107. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

110 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1....

111 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 h...

112 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...

113 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 s...

114 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the 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...

115 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.• Demand drive unit (front gearcase)• Rear gearcase (if equipped)• Transmission• Brake fluid (change every two years and...

116 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 t...

117 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in PARK.3. Secure the fuel cap, oil cap and seat. 4. Turn the fuel valve off. 5. Remove the key to prevent loss during transporting. 6. Always tie the frame of ...

118 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN 500 Touring International Maximum Weight Capacity 568 lbs. (258 kg) (includes operator, passenger, cargo, accessories) Dry Weight 791 lbs. (359 kg) Front Rack/Storage Box Capacity 90 lbs. (41 kg)Rear Rack Capacity 180 lbs. (82 kg) Receiv...

119 SPECIFICATIONS Clutching (EBS Models) *EBS models require no helix/spring adjustment Jetting Chart SPORTSMAN 500 Touring International Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate...

120 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 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gear...

121 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...

122 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, 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 Possible Ca...

123 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...

124 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 (if equipped) Overuse of choke Inspect, clean and/or replace spark p...

125 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 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. PRODUCT IDENTIFIC...

126 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 par...

128 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 or abuse; improper component alignment, te...

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 TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states...

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

132 INDEX 0-9 4X4 System . . . . . . . . . . . . . . . . . 30-31 A Accessories . . . . . . . . . . . . . . . . . . 116 Age Restrictions. . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . 90 All Wheel Drive Switch. . . . . . . . . . 22 All Wheel Drive System . . ....