Polaris Sportsman 500 2008 Service Manual

2008 SPORTSMAN 500 EFI / X2 / TOURING / 500 H.O.

SERVICE MANUAL

FOREWORD

This service manual is designed prim arily for use by ce rtified Polaris M aster Service Dea ler technician s in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Cert ain pro cedures require the use of special tools. Use only the proper tools as specified.

Comments or suggestions about this manual may b e directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2008 Sportsman 500 EFI / X2 / Touring / 500 H.O. Service Manual PN 9921315

© Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication . Due to const ant improvements in the design and quality of production component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation presented in t his

publication. Depictions and/or procedures in this publ ication are intended for reference use only. No liability can be accepted fo r omissions or inaccuracies. Any r eprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

GENERAL

MAINTENANCE

ENGINE

FUEL SYSTEM

BODY / SUSPENSION

CLUTCH

TRANSMISSION

FINAL DRIVE

BRAKES

ELECTRICAL

INTERNATIONAL

NOTES

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE AND MACHINE SERIAL NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

2008 SPORTSMAN 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

MODEL NUMBER: A08MH50AX, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

2008 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL NUMBER: A08MN50AF, AN, AQ, AS, AX. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

2008 SPORTSMAN X-2 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

MODEL NUMBER: A08TN50AX, AZ / A08TN50EA . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

2008 SPORTSMAN TOURING 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

MODEL NUMBER: A08DN50AF, AS, AZ / A08DN50EA. . . . . . . . . . . . . . . . . . . . . . . .1.10

MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

1.1

GENERAL INFORMATION

MODEL NUMBER INFORMATION

Model Number

The machine model number must be used with any correspondence regarding warranty or service.

A08 MN 50 AX

Engine Designation Numbers

EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start

Vehicle Identification Number (VIN)

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A M N 5 0 A * 8 P 0 0 0 0 0 0

Vehicle Descriptor

}

Vehicle Identifier



Body Style

Transmission I.d. Location

Engine And Machine Serial Numbers

The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow.

Engine

Powertrain

Emissions

The transmission I.D.number is located on top of the transmission snorkel, right side of machine.

Model

Year

Check Digit

Plant No

Individual Serial Number

* This could be either

a number or a letter

The machine serial number is stamped on the lower left side of the frame tube (B).

1.2

Publications

GENERAL INFORMATION

Table 1-1: Publications

Year Model Model No.

2008 Sportsman 500 A08MH50A 9921161 9921555 2008 Sportsman 500 EFI A08MN50A 9921477 9921355 2008 Sportsman X2 500 EFI A08TN50A 9921436 9921437

A08DN50A A08DN50E

A08TN50E

2008

Sportsman Touring 500 EFI

Touring Quadricycle

X2 Quadricycle

Owner's

Manual PN

9921436 9921437

Parts

Manual PN

Paint Codes

Table 1-2: Paint Codes

PAINTED PART

Sportsman Frame Black 9440 P-067

COLOR

DESCRIPTION

DITZLER NUMBER

POLARIS NUMBER

Replacement Keys

Replacement keys can be made from the original key (Phoenix excluded). To identify which series the key is, take the first two digits on the original key and refer to the chart to th e right for the proper part num ber. Should both keys become lost, ignition switch replacement is required.

Table 1-3: Key Numbers

Series # Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

Key Cover PN 5433534

1.3

GENERAL INFORMATION

2008 SPORTSMAN 500

Model Number: A08MH50AX, AZ

Engine Model: EH50PLE

Table 1-4: Sportsman 500 General

Specifications

Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1210 lbs./549 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

Rear rack capacity and tongue weight

not to exceed 180 lbs./82 kg

1.4

GENERAL INFORMATION

Table 1-5: Sportsman 500

ENGINE

Platform Fuji Single Cylinder Engine Model Number EH50PLE Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50-90 psi Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Carburetor Mikuni BST 40mm Main Jet 155 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 2 Turns Out (initial) Pilot Air Jet 160 Float Height 14.7mm  1 (.58  0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 19.9 liters

Electrical

Alternator Output 260 w @ 3000 RPM

Voltage Regulator 3-phase - PDM

Lights : Pod 50 watts Grill 2 x 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 13 watts Indicator 1 watt Operating RPM

Ignition System DC/CDI Ignition Ignition Timing

Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Maintenance-Free / 12 Amp Hr.

Circuit Protection Solid State - PDM

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

W/Compression Release

1100

 50 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

or 89 Oxygenated

°2° BTDC @ 5000 RPM

Table 1-6: Sportsman 500

Drivetrain

Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT Non-EBS Belt 3211077

23.91:1

16.30:1

10.49:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

w/ 2

" Coil-over shock

Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment

Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only

Table 1-7: Sportsman 500 Jetting

AMBIENT TEMPERATURE

M e t e r s

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000-12000)

Below 40

Below 5 ° C

° F

+40 to +80 ° F

+5 to +28 ° C

160 155

152.5 147.5

Table 1-8: A08MH50A Clutching

M e t e r s

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight

10 WH

(5630710)

10 RH

(5630709

Drive Clutch Spring

Blu/Grn

(7041157)

Blu/Grn

(7041157)

Driven Clutch Spring

Black

(7041782)

Black

(7041782)

Driven-

Helix

41-37

2+2

(5132344)

41-37

2+2

(5132344)

1.5

GENERAL INFORMATION

2008 SPORTSMAN 500 EFI

Model Number: A08MN50AF, AN, AQ, AS, AX

Engine Model: EH50PLE

Table 1-9: Sportsman 500 EFI General

Specifications

Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1200 lbs./544 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

Rear rack capacity and tongue weight

not to exceed 180 lbs./82 kg

1.6

GENERAL INFORMATION

Table 1-10: Sportsman 500 EFI

ENGINE

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 10 micron in-line

30 micron in tank Fuel Injector(s) Visteon EFI Controller Visteon Fuel Capacity / Requirement 4.13 gal US / 15.63 liters

Electrical

Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt Operating RPM

Ignition System DC/CDI Ignition Ignition Timing

Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

amp / Fuel Pump 10 amp / ECU

15 amp / Ignition Coil 10 amp /

W/Compression Release

1100

 200 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

(not replaceable)

or 89 Oxygenated

° BTDC @ 1150 RPM

Accessory Power 10 amp /

Lights 20 Amp

Table 1-11: Sportsman 500 EFI

Drivetrain

Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT (Standard Models)

PVT w/EBS (Deluxe Models)

Belt 3211113 EBS

23.91:1

21.74:1

10.57:1

3.82:1

3211077 Non-EBS

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment

Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156 Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only

Table 1-12: A08MN50A Clutching

Altitude Shift

M e t e r s

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Weight

10 WH

(5630710)

10 RH

(5630709)

Drive Clutch Spring

Blu/Green (7041157)

Driven Clutch Spring

Red

(3234451)

Red

(3234451)

Helix*

*No

Adjustment

EBS

(3234356)

EBS

(3234356)

1.7

GENERAL INFORMATION

2008 SPORTSMAN X-2 500 EFI

Model Number: A08TN50AX, AZ / A08TN50EA

(Intl’ Quadricycle)

Engine Model: EH50PLE

Table 1-13: Sportsman X-2 500 EFI General

Specifications

Category Dimension / Capacity Length 93 in./236 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 798 lbs./362 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

Rear box capacity and tongue weight

not to exceed 400 lbs./181kg

1.8

GENERAL INFORMATION

Table 1-14: Sportsman X2 500 EFI

ENGINE

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 30 micron in tank Fuel Injector(s) Visteon EFI Controller Visteon Fuel Capacity / Requirement 6 gal US / 22.7 liters

Electrical

Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt

Operating RPM Ignition System DC/CDI Ignition Ignition Timing Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

amp / Fuel Pump 10 amp / ECU

15 amp / Ignition Coil 10 amp /

W/Compression Release

1150

 50 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

(not replaceable)

or 89 Oxygenated

° BTDC @ 1150 RPM

Accessory Power 10 amp /

Lights 20 Amp

Table 1-15: Sportsman X2 500 EFI

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT w/EBS Belt 3211113

23.91:1

21.74:1

10.57:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 8.75 in. / 22.2 cm Ground Clearance 11 in. / 28 cm Shock Preload Adjustment

Front / Rear Turning Radius 82 in./208 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel Size / Pattern - Front Steel 12x6 / 4-156 Wheel Size / Pattern - Rear Steel 12x8 / 4-156 Front Tire Size 25x8-12 Rear Tire Size 25x11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc

Table 1-16: A08TN50A Clutching

Altitude Shift

M e t e r s

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Weight

10 WH

(5630710)

10 RH

(5630709)

Drive Clutch Spring

Blu/Green (7041157)

Driven Clutch Spring

White/Yel (7041635)

Helix*

*No

Adjustment

EBS

(5131674)

EBS

(5131674)

1.9

GENERAL INFORMATION

2008 SPORTSMAN TOURING 500 EFI

Model Number: A08DN50AF, AS, AZ / A08DN50EA

(Intl’ Quadricycle)

Engine Model: EH50PLE

Table 1-17: Sportsman Touring 500 EFI

General Specifications

Category Dimension / Capacity Length 86 in./218 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 770 lbs./349 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./82 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

Rear rack capacity and tongue weight

not to exceed 180 lbs./82 kg

1.10

GENERAL INFORMATION

Table 1-18: Sportsman Touring 500 EFI

ENGINE

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Electrical

Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt

Operating RPM Ignition System DC/CDI Ignition Ignition Timing Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

amp / Fuel Pump 10 amp / ECU

15 amp / Ignition Coil 10 amp /

W/Compression Release

1150

 50 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

(not replaceable)

or 89 Oxygenated

° BTDC @ 1150 RPM

Accessory Power 10 amp /

Lights 20 Amp

Table 1-19: Sportsman Touring 500 EFI

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT w/EBS Belt 3211113

23.91:1

21.74:1

10.57:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 8.75 in. / 22.2 cm Ground Clearance 11 in. / 28 cm Shock Preload Adjustment

Front / Rear Turning Radius 82 in./208 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Table 1-20: A08DN50A Clutching

Altitude Shift

M e t e r s

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Weight

10 WH

(5630710)

10 RH

(5630709)

Drive Clutch Spring

Blu/Green (7041157)

Driven Clutch Spring

White/Yel (7041635)

Helix*

*No

Adjustment

EBS

(5131674)

EBS

(5131674)

1.11

GENERAL INFORMATION

MISC. NUMBERS/CHARTS

Standard Torque Specifications

The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

1.12

GENERAL INFORMATION

SAE Tap Drill Sizes

Thread Size/ Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

Metric Tap Drill Sizes

Tap Size Drill Size

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Decimal Equivalent

Nearest Fraction

Decimal Equivalents

1/64 . . . . . . . . . . .. . . . . . . .0156

1/32 . . . . . . .. . . . . . . .0312 . . 1 mm= .0394"

3/64 . . . . . . . . . . .. . . . . . . .0469

1/16 . . . . . . .. . . . . . . .0625

5/64 . . . . . . . . . . .. . . . . . . .0781 . . 2 mm = .0787"

3/32 . . . . . . .. . . . . . . .0938

7/64 . . . . . . . . . . .. . . . . . . .1094 . . 3 mm =.1181"

1/8 . . . . . . . . .1250

9/64 . . . . . . . . . . .. . . . . . . .1406

5/32 . . . . . . .. . . . . . . .1563 . . 4 mm = .1575"

11/64 . . . . . . . . . . .. . . . . . . .1719

3/16 . . . . . . .. . . . . . . .1875 . . 5mm= .1969"

13/64 . . . . . . . . . . .. . . . . . . .2031

7/32 . . . . . . .. . . . . . . .2188

15/64 . . . . . . . . . . .. . . . . . . .2344 . . 6 mm = .2362"

1/4 . . . . . . . . .25

17/64 . . . . . . . . . . .. . . . . . . .2656 . . 7 mm = .2756"

9/32 . . . . . . .. . . . . . . .2813

19/64 . . . . . . . . . . .. . . . . . . .2969

5/16 . . . . . . .. . . . . . . .3125 . . 8mm= .3150"

21/64 . . . . . . . . . . .. . . . . . . .3281

11/32 . . . . . .. . . . . . . .3438 . . 9 mm = .3543"

23/64 . . . . . . . . . . .. . . . . . . .3594

3/8 . . . . . . . . .375

25/64 . . . . . . . . . . .. . . . . . . .3906 . . 10 mm = .3937"

13/32 . . . . . .. . . . . . . .4063

27/64 . . . . . . . . . . .. . . . . . . .4219 . . 11 mm =.4331"

7/16 . . . . . . .. . . . . . . .4375

29/64 . . . . . . . . . . .. . . . . . . .4531

15/32 . . . . . .. . . . . . . .4688 . . 12 mm = .4724"

31/64 . . . . . . . . . . .. . . . . . . .4844

1/2 . . . . . . . . .5 . . . . . . . . . . . 13mm = .5118"

33/64 . . . . . . . . . . .. . . . . . . .5156

17/32 . . . . . .. . . . . . . .5313

35/64 . . . . . . . . . . .. . . . . . . .5469 . . 14 mm = .5512"

9/16 . . . . . . .. . . . . . . .5625

37/64 . . . . . . . . . . .. . . . . . . .5781 . . 15 mm = .5906"

19/32 . . . . . .. . . . . . . .5938

39/64 . . . . . . . . . . .. . . . . . . .6094

5/8 . . . . . . . . .625 . . . . . . . . . 16mm=. 6299"

41/64 . . . . . . . . . . .. . . . . . . .6406

21/32 . . . . . .. . . . . . . .6563 . . 17 mm =.6693"

43/64 . . . . . . . . . . .. . . . . . . .6719

11/16 . . . . . .. . . . . . . .6875

45/64 . . . . . . . . . . .. . . . . . . .7031 . . 18 mm = .7087"

23/32 . . . . . .. . . . . . . .7188

47/64 . . . . . . . . . . .. . . . . . . .7344 . . 19 mm = .7480"

3/4 . . . . . . . . .75

49/64 . . . . . . . . . . .. . . . . . . .7656

25/32 . . . . . .. . . . . . . .7813 . . 20 mm = .7874"

51/64 . . . . . . . . . . .. . . . . . . .7969

13/16 . . . . . .. . . . . . . .8125 . . 21 mm =.8268"

53/64 . . . . . . . . . . .

27/32 . . . . . .. . . . . . . .8438

55/64 . . . . . . . . . . .. . . . . . . .8594 . . 22 mm = .8661"

7/8 . . . . . . . . .875

57/64 . . . . . . . . . . .. . . . . . . .8906 . . 23 mm = .9055"

29/32 . . . . . .. . . . . . . .9063

59/64 . . . . . . . . . . .. . . . . . . .9219

15/16 . . . . . .. . . . . . . .9375 . . 24 mm = .9449"

61/64 . . . . . . . . . . .. . . . . . . .9531

31/32 . . . . . .. . . . . . . .9688 . . 25 mm = .9843"

63/64 . . . . . . . . . . .. . . . . . . .9844

1. . . . . . . . . . 1.0

. . . . . . . .8281

1.13

GENERAL INFORMATION

Conversion Table

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

(3.14)xR

x H (height) = Cylinder Volume

°C to °F: 9 (°C + 40) 5 - 40 = °F °F to °C: 5 (°F + 40)

 9 - 40 = °C

1.14

Glossary Of Terms

GENERAL INFORMATION

ABDC: After bottom dead center. ACV: Alternating current voltage.

ADC: Active Descent Control. Alternator: Electrical generator producing voltage alternating current.

ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between

centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare

wire touching the chassis).

Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Ft. lb. / Foot Pound: A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. Left Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a m agnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,. Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. PDM: Power Distribution Module. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. RPM:

Revolutions per minute.

Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat. Right Side: Always referred to based on normal operating position of the driver. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of alumi num from the piston onto the cy linder wall.

Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.15

GENERAL INFORMATION

NOTES

1.16

MAINTENANCE

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

LUBRICATION / FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

SPORTSMAN COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

SPORTSMAN X2-TOURING COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .2.8

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.9

POLARIS LUBRICANT SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

LUBRICATION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE. . . . . . . . . . . . . . . . . . .2.14

VEHICLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

SHIFT LINK ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT . . . . . . .2.15

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

CHOKE (ENRICHER) ADJUSTMENT - (500 CARB). . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ACTIVE DESCENT CONTROL (ADC) RESERVOIR LEVEL. . . . . . . . . . . . . . . . . . . . . 2.18

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

RADIATOR/GRILL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

AIR BOX SEDIMENT TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

BREATHER FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

BREATHER HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

WHEEL ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

2.1

MAINTENANCE

HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

AUXILIARY BRAKE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

WHEEL REMOVAL FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STORAGE COMPARTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

WINCH OPERATION (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

ATV CLEANING & STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

SPORTSMAN 500 CARBURETED MAINTENENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39

IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39

FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40

MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41

2.2

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 parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustment s are critical. If you’re not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operatio ns .

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can ind icate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine th e cau se or se e you r dea ler.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.

= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or exte nde d idle. More pre ven tati ve maint enance is r equire d under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes se vere use. Pay specia l attention to oil lev el. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E= Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with a

 could result in component failure and lead to

serious injury or death. Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

 Steering - Pre-Ride -

Front-suspension - Pre-Ride -



Rear-suspension - Pre-Ride -



Tires - Pre-Ride -



ADC fluid level - Pre-Ride -



Brake fluid level - Pre-Ride -



Brake lever travel - Pre-Ride -



Brake systems - Pre-Ride Wheels /fasteners - Pre-Ride Frame fasteners - Pre-Ride -



Engine oil level - Pre-Ride -

Passenger Seat Lock Out - Pre-Ride - Verify Seat is secured Dump Box Operation - Pre-Ride - Verify Box is latched



Air filter, pre-filter - Daily - Inspect; clean often



Air box sediment tube - Daily - Drain deposits when visible

Coolant - Daily -

Headlamp/tail lamp - Daily Air filter,



main element

Recoil housing - Weekly -



Brake pad wear 10 H Monthly 60 (100) Inspect periodically



Battery 20 H Monthly 125 (200) Check terminals; clean; test Front gearcase oil (if



equipped) Middle gearcase oil (if



equipped) Rear gearcase oil



(if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly



- Weekly - Inspect; replace as needed

25 H Monthly 155 (250) Inspect level; change yearly

Make adjustments as needed.

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

Drain water as needed, check often if operating in wet conditions

Remarks



Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

2.4

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Engine breather



filter (if equipped)

Engine oil change



(break-in)

General



lubrication Shift Linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust

 Steering 50 H 6 M 310 (500) Lubricate

Front suspension 50 H 6 M 310 (500) Lubricate



Rear suspension 50 H 6 M 310 (500) Lubricate





Throttle Cable/ETC

Switch Air intake ducts/

flange Drive belt 50 H 6 M 310 (500) Inspect; adjust; replace as needed Cooling system (if applicable) Engine oil change



Oil filter change 100 H 6 M 620 (1000) Replace with oil change



Oil tank vent hose 100 H 12 M 620 (1000) Inspect routing, condition



Valve clearance 100 H 12 M 620 (1000) Inspect; adjust

25 H Monthly 155 (250) Inspect; replace if necessary

25 H 1 M 155 (250)

50 H 3 M 310 (500)

50 H 6 M 310 (500) 50 H 6 M 310 (500)

50 H 6 M 310 (500)

100 H 6 M 620 (1000)

Perform a break-in oil change at one month

Lubricate all grease fittings, pivots, cables, etc.

Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks

Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at 25 hours/one month

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

2.5

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)



Fuel system 100 H 12M



Fuel Filter 100 H 12M

Radiator



(if applicable) Cooling hoses



(if applicable) Engine mounts 100 H 12M



Exhaust muffler / pipe



Spark plug 100 H 12M



Ignition Timing 100 H 12M

Wiring 100 H 12M



Clutches (drive



and driven) Front wheel



bearings

 Brake fluid 200 H 24M

Spark arrestor 300 H 36M

 Toe adjustment - Inspect periodically; adjust when parts are replaced



Auxiliary brake - Inspect daily; adjust as needed



Headlight aim - Adjust as needed

100 H 12M

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

1000

(1600)

1240

(2000)

1860

(3000)

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years

Replace yearly

Inspect; clean external surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect Inspect for wear, routing, security; apply dielectric

grease to connectors subjected to water, mud, etc. Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

2.6

LUBRICATION / FLUIDS

SPORTSMAN Component Locations

MAINTENANCE

(Deluxe)

Choke - 500 Carburetor

(Sportsman Only)

2.7

MAINTENANCE

SPORTSMAN X2-Touring Component locations

(Sportsman X2 Shown)

Brake Fluid Reservoir

Brake Lever

Worklight

Instrument Cluster

(Speedometer)

AWDSwitch

Diagnostic Port (under access panel)

Front Storage Compartment & Rack

Front Demand

Drive Unit

(Behind Radiator)

Light Control & Run Switch

Oil Dipstick

PVT Cover

Gear Shifter

Reverse Override

Gas Cap

Throttle

Differential Lock Switch

Ignition/Key

X2 Rear Dump Box / Passenger Area

Battery (Under Tank)

2.8

Transmission

Rear Drive CV Shafts

Right Side View

Muffler

Auxiliary Brake

Front Prop Shaft

(Between Transmission and Front Gearcase)

Front Drive CV Shafts

MAINTENANCE

Polaris Lubricants, Maintenance and Service Products

Table 2-1:

PART

NUMBER

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2876244

2876245

Gearcase / Transmission Lubricants 2876251 Demand Drive L T Premium Hub Fluid 2867144 Polaris ADC Hydraulic Fluid

2873602

2873603

2876160

2872276 2870465 Oil Pump for 1 Gallon Jug

2871322

2871423 2871460 Starter Drive Grease (12 count) 2871515

2871551 2871312 Grease Gun Kit

2871329

Engine Oil (Quart) Premium Synthetic

Engine Oil (Gallon) Premium Synthetic

Premium Synthetic AGL Gearcase Lube

Premium ATV Angle Drive Fluid

Grease / Specialized Lubricants

DESCRIPTION

2W-50 (4-cycle) (12 count)

2W-50 (4-cycle) (4 count)

(12 oz. bottle) (12 count)

(1 Gal. bottle) (4 count)

(32 oz.) (12 count)

(2.5 Gal.) (2 count)

Premium All Season Grease

(3 oz. cartridge) (24 count)

Premium All Season Grease (14 oz. cartridge) (10 count)

Premium U-Joint Lube

(3 oz.) (24 Count)

Premium U-Joint Lube

(14 oz.) (10 count)

Dielectric Grease (Nyogel



Table 2-1:

PART

NUMBER

2871323 60/40 Coolant (Gallon) (6 count) 2871534 60/40 Coolant (Quart) (12 count)

Additives / Sealants / Thread Locking Agents / Misc.

2874275 2871956

2871950

2871951

2871953

2871557

2871326 2870652 Fuel Stabilizer (16 oz.) (12 count) 2871957

2871958 2872189 DOT 4 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)

DESCRIPTION

Coolant

Loctite

Primer N, Aerosol

Loctite

Thread Sealant 565

(50 ml.) (6 count)

Loctite

 Threadlock 242

(6 ml.) (12 count)

Loctite

 Threadlock 262

(50 ml.) (10 count)

Loctite

 Threadlock 271

(6 ml.) (12 count)

3-Bond 1215

Premium Carbon Clean

(12 oz.) (12 count)

Black RTV Silicone Sealer

(3 oz. tube ) (12 count)

Black RTV Silicone Sealer

(11 oz. cartridge) (12 count)

Sealant

(5 oz.)

2.9

MAINTENANCE

Polaris Lubricant Symbol Identification

NOTE: The symbols used are for quick reference in identifying which lubricant/grease to use on each component.

Polaris DOT 4 Brake Fluid

Polaris ADC

Hydraulic Fluid

Polaris Synthetic

2W/50

Polaris ATV Angle Drive Fluid

Polaris Synthetic AGL

Gearcase Lube

Polaris 60/40

Coolant

Polaris Demand Drive

LT Hub Fluid

Pre-ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Verify seat lock-out operation

• Verify box lock-out operation

• Tires - check condition and pressures

• Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank

• All brakes - check operation and adjustment (includes auxiliary brake)

• Throttle -check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

Polaris U-Joint Lube

Polaris All

Season Grease

• Engine coolant - check for proper level at the recovery bottle

• ADC Fluid Level - check for proper level

2.10

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