Manuale d’uso / di manutenzione del prodotto Sportsman 9921309 del fabbricante Polaris
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For your nearest P olaris dealer , call 1-800-POL ARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 P art No. 9921309 Rev 02 Printed in USA P antone 626 cvc Improper vehicle use can result in SEVERE INJUR Y or DEA TH.
W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth defects or other reproductive harm.
1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products.
2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F e atures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . .
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5 KNOW Y OUR VEHICLE As the operator of the vehicle, yo u are responsible for yo ur personal safety , the safety of others, and the protection of our enviro nment. Read and understand your o wner's manual, which includes valuable info rma- tion abou t all aspects of your vehicle, incl uding safe operating proce- dures.
6 SAFETY Safety Decals and Locations W arning decals have been placed on the A TV for your protection. Read and follow the instructions of the de cals on the A TV caref ully . If any of the decals depicted in this manual dif fer from the decals on your A TV , always read and follow the instructions of the decals on the A TV .
7 SAFETY Safety Decals and Locations Tire Pressure/Load W arning WARNING IMPROPER TIRE PRES SURE OR OVER L OADING can cause loss of control resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KP a): FRONT 5 (3 4.5) CENTER 5 (34 .5) REAR 5 (34.
8 SAFETY Safety Decals and Locations Age 16 W arning WARNING Operating this A T V if you are under th e age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. Container/No P assenger W arning WARNING Remove flammable containers from box before refueling.
9 SAFETY Safety Decals and Locations All Wheel Drive Switch Do not push switch to engage AWD if th e rear wheels are spi nning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. Hitch Capacity Label TRAILER MAX WEIGHT : 1500 LBS.
10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the chance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
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 goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.
12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WA R NI N G F ailure to fo llow the warnings contained in this manual can result in severe injury or death.
13 SAFETY Operator Safety Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchased your new A TV , your deal er instructed you on the authorized A TV RiderCourse sm available to yo u and your e ligible family members. This training is included in the purchase price of your A TV .
14 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used.
15 SAFETY Operator Safety • Read this manual and all labels carefully , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV RiderCourse sm .
16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as de scribed in this manual.
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 procedu res when operating over obstacles as described in this manual.
18 SAFETY Operator Safety Equipment Modifications W e are concerned for th e safety of our customers and for the general public. Therefore, we strongly reco mmend that consumers do not install on a Polaris A TV any equipment that may increase the speed or power of the vehicle, or make any other m odifications to the vehicle for these purposes.
19 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Opera ting this A TV without pr oper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the A TV properly in different situ ations and on different types of terrain .
20 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Carrying a pa ssenger on an A TV . WHA T CAN HAPPEN Carrying a pa ssenger greatl y reduces the operator's abil ity to balance and control the A TV , which could cause a n accident and injury to the opera tor and/or pa ssenger .
21 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZAR D Never operate the A TV on any public street, road or highway , inclu ding dirt and gravel roads.
22 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating the A T V after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator jud gment. Reaction time may be slower and operator bala nce and perception co uld be affected.
23 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts in creases the chance of an accident, including an overturn. HOW TO A VOID THE HAZAR D Never attempt jumps or other stunts. Avoid exhibition driving.
24 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Removing hands from the handleba rs or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce abili ty to control th e vehicle or could cause loss of balance and ejection from the A TV .
25 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD F ailure to use extra caution when operating on excessivel y rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on e xcessively rough, slippery or loose terrain could cause loss of traction or lo ss of control, which could result in an accident or overturn.
26 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating on e xcessively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZAR D Never operate on hills too steep for the A TV or fo r your abilities. Never operate the A TV on hills steeper than 15 degrees.
27 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZAR D Always follow proper procedures for traveling down hills as describ ed in the owner's manual.
28 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting whil e climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZAR D Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
29 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Improperly operating over obstacl es. WHA T CAN HAPPEN Operati ng over obstacle s could cause loss of cont rol or overturn. HOW TO A VOID THE HAZAR D Before operating in a ne w area, check for obstacles.
30 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating the A T V through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO A VOID THE HAZAR D Avoid operating the A T V through deep or fast-flowin g water .
31 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Operating this A T V with improper tires, or with improper or uneven tire pressure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improp er or uneven tire pressure, could cause loss of control or accident.
32 SAFETY Operator Safety WA R NI N G POTENTIAL HAZARD Overloading the A TV or carrying/ towing carg o improperly . WHA T CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could le ad to loss of control or a n accident. HOW TO A VOID THE HAZAR D Never exceed the stated load capacity for this A TV .
33 SAFETY Operator Safety WA R NI N G Operating a da maged A T V can result in an accident with serious injury o r death. Afte r any overturn or accid ent, have a qualified service dealer inspect the entire ma chine for possible dama ge, including (but not limited to) brakes, throttle and st eering systems.
34 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional power while backing, depress the override switch. NOTE: The override sw itch also allows activati on of All Wheel Drive in reverse, if the AWD switch is on.
35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch to the center (OFF) position to stop the engine quickly . The st op switch provides the operator with a quick means of engine shutdown in case of stuck throttle or other emergency .
36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are contro lled by pressing the throttle lever . The throttle lever is spring loaded.
37 FEA TURES 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.
38 FEA TURES 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 A TV . The fluid level can be seen through an indi cator window on the top of the master cylin- der .
39 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking 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. T o rele ase the parking brake lock, squeeze and release the brake lever .
40 FEA TURES AND CONTROLS Fu e l T a n k C a p Remove the fuel tank cap to a dd fuel to the fuel tank. Us e eith er leaded o r unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. F uel V alve The fuel valve is located on the left side panel.
41 FEA TURES AND CONTROLS T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse To change gears, stop the vehi- cle, and with the engine idling, move the lever to the desired gear.
42 FEA TURES 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.
43 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The Al l Wheel Drive sy stem is controlled by the A WD switch. When the switch is of f, the vehi- cle is in rear wheel drive at all times. When the switch is on, the vehicle is in A WD an d the front wheels will automatic ally engage any time the rear wheels lose trac- tion.
44 FEA TURES AND CONTROLS All Wheel Drive (A WD) System Disengaging Wheel Hubs The hubs no rmally disengage when operating in reverse. However , one or both hubs may occasionally rema in engaged. If the handlebars pull to one side, one front hub is engaged.
45 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. Th e ins trument cluster me asures dis- tance in miles or kilometers as well as hours of operation.
46 FEA TURES 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.
47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Mode s The rider information center has 4 st anda rd modes. The reverse override button on the left handleba r is also the mode button.
48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only . Plea se return your A TV to your dealer for all major repairs. As long as the gauge is in the diag nosti c mode, the wrench icon will remain lit.
49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Scr een 5: Programmable service interval The purpose of the pro grammable serv ice interval is to provide the con- sumer and dealer with a conven ient reminder fo r routine maintenance.
50 OPERA TION F uel Safety WA R NI N G Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme cautio n whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventil ated area.
51 OPERA TION Break-In P eriod The break-in period for your new Polaris A TV is the first ten ho urs of operation, or the time it takes to use the first two full ta nks of gasolin e. No single action on your part is as important as foll owing the proce- dures for a proper break-in.
52 OPERA TION Pre-Ride Checklist WA R NI N G If a proper inspection is not done befor e ea ch use, severe injury or death could result. Always in spect the vehicl e before each use to ensure it's in proper operating co ndition.
53 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking bra ke. NOTE: The starte r interlock will prevent the en gine from starting if the trans- mission is in gear and th e brake is not engaged.
54 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage the star ter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. 9. If the engine do es not start, return the key to the OFF position and wait five seconds before attemptin g to start again.
55 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load distri bution warning labels on th e vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety decals.
56 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the car go. Do not attempt to dump or unload the vehicle while park ed on an incline. 2. Lock the parking bra ke. 3. Dismount the vehi cle. 4. Check car go distribution. If car go has shifted to the rear of the box, exercise caution.
57 OPERA TION Hauling Cargo Load Distribution 1. Never exceed the maximum capac ities for hauling car go as stated on the load distrib ution warning labels and o n page 55. 2. Always load the cargo box with th e load as far forward as possible. 3. Always operate the vehicle with extreme caution whenever hauling or towing loads.
58 OPERA TION Driving Safely Driving Procedures 1. W ear protec tive riding gear . See page 10. 2. Sit upright with both feet on th e foo trests and both hands on the handlebars. 3. S tart the engine and allow it to warm up. See page 53. 4. Shift the transmission into gear .
59 OPERA TION Driving Safely T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives all rear wheels equally at al l times. This means that the wheel on the outside of the turn must travel a greater d istance tha n the inside wheel when turning and the inside tire must slip traction slightly .
60 OPERA TION 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 wh en enter- ing slippery areas. 2. Engage A WD before wheels begin to lose traction.
61 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (15 ° maximum). 3. Keep both feet on the footrests . 4. Shift your weight uphill. 5. Proc eed at a steady rate of speed and t hrottle opening.
62 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can dangerous and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill.
63 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill.
64 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the park ing brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine .
65 OPERA TION Driving Safely Driving Through W a ter Y our A TV can operate throu gh water with a maximum recom- mended dep th equal to the bot- tom of the footrests. Follow these procedures when operat- ing throug h water: 1. Determine water depths and current before crossing.
66 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for ha zards such as logs, rocks and low hanging branches. WA R NI N G Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
67 OPERA TION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the veh icle. 2. Always avoid bac king downhill . 3. Back slowly . 4. Apply the brakes lightly for stopping.
68 OPERA TION Driving Safely P arking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking bra ke. 4. Always block the rear wh eels on the downhill side.
69 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requi rements (40 CFR 205.158) and lo cal noi se level requirements. Operation on Public Lands in the U.
70 MAINTENANCE P eriodic Maintena nce Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance chart .
71 MAINTENANCE P eriodic Maintena nce Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions .
72 MAINTENANCE P eriodic Maintena nce Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
73 MAINTENANCE P eriodic Maintena nce Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
74 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 70.
75 MAINTENANCE Lubrication Recommendations F ront Prop S haft Y oke AWD Hubs Ball Joint Middle Axle Bearings Center Swing Arm Housing Swing Arm Bushings Rear Axle Bearing Rear Stru t Tie Rod Ends 4:00.
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 Polari s oil is not used. Always use 2W -5 0 oil.
77 MAINTENANCE Engine Oil Oil Level The oil dipstick is on the left side of the A TV . 1. Position the vehicle on a level surface. 2. S tart the engine. Allow it to idle for 20-30 seconds. S top the engine. 3. Remove the dipstick. W ipe it dry with a clean cloth.
78 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 70. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2.
79 MAINTENANCE Oil and Filter Change 8. Reinstall the screen fitting and ro tate the fitting clockwise a mini- mum of 2 1/2 turns into the tank thr eads. Continue to rotate the fit- ting until the nipple of the fitting aligns with the mark on the tank.
80 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must b e performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.
81 MAINTENANCE T ransmission Oil Always check and ch ange the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. W e recommend the use of Polaris Premium AGL Synthe tic Gearcase Lubricant.
82 MAINTENANCE F ront 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 oi l level at the bottom of the fill hole threads. W e reco mmend the use of Polaris Premium A TV Angle Drive Fluid.
83 MAINTENANCE Cooling System The engin e coolant level is controlled, or main tained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
84 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s 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 coo ling system has been drained for maintenance or repair .
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 .
86 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) to e out. 1. Position the vehicle on a level surface. 2. Place the hand lebars in a straight-ahead positi on.
87 MAINTENANCE Steering Assembly The steering assemb ly of the A TV should be che cked periodically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the veh icle. Side P anel Removal 1.
88 MAINTENANCE Tires Refer to the specifications section beginning on page 124 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. S top the engine.
89 MAINTENANCE Tires Wheel Installation 1. Place the transmission in gear . 2. Lock the parking bra ke. 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.
90 MAINTENANCE Air Filter Always inspect and replace the air fi lter at the intervals outlined in the Periodic Maintenance Char t beginni ng 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 .
91 MAINTENANCE Breather Filter/Hose Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Ch art beginn ing 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 the engine.
92 MAINTENANCE Lights When servicing a ha logen 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 lowe r front corners of the headlight pod.
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 su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wal l.
94 MAINTENANCE Lights Headlight Housin g Replacement 1. Remove the two screws on the lowe r 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 disconn ect the speedome ter harnesses from the speedometer .
95 MAINTENANCE Lights T aillight/Brakelight Lamp Replace ment 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.
96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifi cations section beginning on p age 124 for the recom- mended spark pl ug type and gap for your vehicle. Always to rque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion.
97 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spar k Plug The normal insulator tip is gray , ta n 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.
98 MAINTENANCE V ehicle Immersion 1. If it's impossible to take yo ur A TV to a dealer before starting it, fol- low the steps outlined below . 2. Move the A TV to dry land or at the very least, to water below the footrests. 3. Check the air bo x.
99 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur g e accumulated carbon from the exha ust pipe /muf fler . 1. Remove the arrestor c lean- out plug from the bottom of the muf fler . 2. Place the transmission in neutral. 3.
100 MAINTENANCE PVT System WA R NI N G F ailure to comply with th e 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 failu re may occur at a high speed.
101 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
102 MAINTENANCE PVT System When T o Use Low Range and High Range PVT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Remove the drain plug.
103 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A seale d battery can be identified by its flat covers on the top of t he battery . A conventional battery has six filler caps on the top of the battery .
104 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last.
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 ca n also hinder vehicle performance. Follow the battery charging instructio ns on page 107 before installing the battery .
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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recharge as needed to mainta in a full char ge.
107 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery char ging instructions apply only to the installa- tion of a sealed battery .
108 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 h ours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top of bat tery) 100% 12.
109 MAINTENANCE Cleaning and Storage W ash ing the V ehicle 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 .
110 MAINTENANCE Cleaning and Storage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution.
111 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recomme nded. See page 109. F og the Engine 1. Support the front end of the machine so t he engine is level or tilted slightly rearward.
112 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as recommen ded in the Periodic Maintenance Chart beg inning on page 70.
113 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 70. Engine Anti-F reeze T est engine coola nt strength and ch ange if necessary .
114 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking bra ke. 4. Secure the fuel cap, oil ca p and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or ro pe.
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 hand lebar bolts. 3. Adjust the handlebar to t he desired heigh t.
116 ADJUSTMENTS Throttle Cable F reeplay 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 .
117 ADJUSTMENTS F ront 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 p ull up and down on the chain. At this point the chain should have 3/16"-3/8" (5-9 mm) deflection.
118 ADJUSTMENTS Rear Axle Drive Chain T o a djust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. T o tal slack for the rear ch ain should be adjusted to 3/6"-3/8" (6-9 mm) at the tightest point in the chain.
119 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrate d at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F .
120 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 64).
121 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.
122 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommended fue l Incorrect ignition tim.
123 TROUBLESHOOTING Engine Stops or Loses P ower Engine Overheating Possible Cause Solution Out of fuel R efuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged f.
124 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 6X6 Maximum W eight 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.
125 SPECIFICA TIONS Clutching Ch art Jetting Chart Sportsman 500 6X6 T ransmission Automatic PVT (H/L/N/R) Gear Reduction, Low 6 .69:1 Gear Reduction, Reverse 5 .
126 POL ARIS PRODUCTS Pa rt Number Description Engine L ubricant 2870791 F og ging Oil (12 oz. Aerosol) 2876244 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.
127 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris Light Utilit y V ehicle against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
128 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris l imited warranty exclude s any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
129 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED T O THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER D ISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARRAN TY .
130 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEA LER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.
131 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in wh ich the vehicle was originally pur chased, a ll warranty coverage will be denied.
132 W ARRANTY California Emission Control W arranty Statement Y our W arranty Rights and Obli gations The California Air Resources Board and Polaris Industries Inc.
133 W ARRANTY California Emission Control W arranty Statement Limited W arranty California Only POLARIS warrants to the owner of 2006 and la ter LSI engines that the LSI engine (1) has been designed, .
134 W ARRANTY California Emission Control W arranty Statement What is Not Covered Un der This Wa rranty This warranty does not cover a ny emission-related part, which malfunctions, fails, or is damaged due to alterations an d/or modifications such as changing, adding, or removing parts.
135 W ARRANTY California Emission Control W arranty Statement Repair and Replac ement of Emission-Related P arts It is recommended that only LS I engine replacemen t p arts, which have been authorized and approved by POLARIS, shoul d be u sed in the performan ce of any warranty mainte- nance or repairs of emission-re lated parts.
136 W ARRANTY U.S.A . EP A Emissions Limited Wa rranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions lim ited warranty is in addition to the Polaris st andard limited warrant y for this vehicle.
137 MAINTENANCE L OG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
138 MAINTENANCE L OG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS.
139 MAINTENANCE L OG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS.
140 INDEX A Age Restrictions . . . . . . . . . . . . . . . . 12 Air Box Drain . . . . . . . . . . . . . . . . . 90 Air Filt er . . . . . . . . . . . . . . . . . . . . . 90 All Wheel Drive Syst em . . . . . . . . . 43 AWD Switch . . . . . . . . . . . .
141 INDEX I Idle RPM Adju stment . . . . . . . . . . . 119 Immersion . . . . . . . . . . . . . . . . . . . . . 98 Instrument Clus ter . . . . . . . . . . . . 45-49 J Jetting Chart . . . . . . . . . . . . . . . . . . 125 K Key Switch . . . . . . . . . .
142 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . 95 Throttle Body Adjustment . . . . . . . 116 Throttle Cable Freeplay . . . . . . . . 116 Throttle Lever . . . . . . . . . . . . . . . . . 36 Tire Tread Depth . . . . . . . . . . . . . .
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Polaris Sportsman 9921309 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Polaris Sportsman 9921309 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Polaris Sportsman 9921309 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Polaris Sportsman 9921309 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Polaris Sportsman 9921309, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Polaris Sportsman 9921309.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Polaris Sportsman 9921309. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Polaris Sportsman 9921309 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
