Polaris Sportsman 9921848 User Manual

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Quadricycles

• RANGER utility vehicles

• Victory motorcycles Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about Polaris, visit us online at www.polarisindustries.com.

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2009 Sportsman 500 X2 Quadricycle Owner’s Manual P/N 9921848

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Emission Control Systems . . . . . . . . . . . . . . . 68

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 128

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 136

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

KNOW YOUR VEHICLE

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.

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 of your existing keys. The ignition switch must be replaced if all keys are lost.

Engine Serial Number

VIN

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

####

Key Number

SAFETY

Rider Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

SAFETY

Rider Safety

WARNING

Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle 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 your owner's manual and all warnings before operating a Polaris Quadricycle.

Safety Training

When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road.

Equipment Modifications

The warranty on your Polaris Quadricycle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers and large racks may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

SAFETY

Rider Safety

WARNING

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle.

Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

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 Quadricycle.

Never carry more than one passenger on this 2-up Quadricycle.

Rider Safety

Never allow a passenger to ride in the cargo box.

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating a Quadricycle.

SAFETY

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Never attempt jumps or other stunts.

SAFETY

Rider Safety

Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 45.

Keep both hands on the handlebars. Keep both feet on the footrests.

A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

Always follow the procedures outlined in this manual for turning. See page 49.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

SAFETY

Rider Safety

If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Always follow the procedures outlined in this manual for driving on hills. See page 52. Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15°.

Never operate with the differential unlocked ( ) while operating on a hill or other irregular terrain. See pages 23 and 31. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 55.

>15°

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 54.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 56.

Always follow the procedures outlined in this manual for operating over obstacles. See page 61.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 60.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page

58.

Rider Safety

Always follow the procedures outlined in this manual for driving in reverse. See page 63.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Never modify a Quadricycle through improper installation or use of accessories.

SAFETY

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

SAFETY

Rider Safety

Never operate the Quadricycle on a frozen body of water.

Operating on paved surfaces may affect the handling and control of the Quadricycle 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 starting.

Always unlock the steering before starting the engine. See page 28.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about Quadricycle safety,

contact an authorized Polaris Quadricycle dealer or

visit the Polaris web site at www.polarisindustries.com.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

The following pages repeat the information found on each decal.

General Alert (Multi-Lingual)

Before you operate or ride this vehicle, read the owner’s manual.

General

Alert

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 15 degrees 15°.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

• Never operate this vehicle in mode on irregular terrain, including hills and obstacles.

Age 16

Alert

Hill

Operation

Alert

SAFETY

Safety Decals and Locations

Reverse Override

Front Rack

Warning

Alert

Clutch

Cover Alert

Box

Warning

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 514 LBS. (233 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND

ACCESSORIES. Read Owner's Manual for more detailed loading information.

Reverse Override Alert

Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in 4X4. See Owner's Manual.

Tire Pressure/

Load Alert

SAFETY

Safety Decals and Locations

Box Warning

WARNING Remove flammable material

containers from box before filling.

WARNING Passengers can be thrown off. This can cause serious

injury or death. Never carry passengers in cargo box. Maximum Box Load - 348 lbs. (158 kg)

Clutch Cover Alert

NO STEP

Front Rack Warning

WARNING - DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Front Rack and Container Load: 90 lbs. (41 kg)

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Long

Sleeves

Boots

Eye Protection

Gloves

Long Pants

Helmet

Always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial

051039

0006.31

number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

FEATURES AND CONTROLS

Switches

Mode/Reverse

Override Switch

Engine Stop Switch

Hazard

Switch

Differential

Switch

Headlight

Switch

Horn Switch

Turn Signal Switch

4X4 Switch

Main Key Switch

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 34.

To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

NOTE: The override switch also allows activation of 4X4 in reverse, if the 4X4

switch is on.

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

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 large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF

RUN

Light Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam

Low Beam

Engine

Stop Switch

Light

Switch

FEATURES AND CONTROLS

Switches

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30.

4X4 Switch

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.

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 to sound the horn.

Hazard Warning

Switch

Horn Switch

Differential

Switch

Tu r n

Indicators

Turn Signal

Switch

FEATURES AND CONTROLS

Switches

Differential Switch

Use the differential switch to lock and unlock the rear differential.

Locked Differential: Operate the vehicle with the switch in the locked position in most conditions.

Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns. Operate with an unlocked differential only as needed to protect smooth, level surfaces from tire damage. Otherwise, move the switch to the locked position. This feature will function only if the vehicle is in 2X4 mode.

Operating with the differential unlocked ( ) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.

DO NOT operate with the differential unlocked ( ) when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Place the differential switch in the locked position and operate in ADC 4X4 or 4X4 on these types of terrain.

FEATURES AND CONTROLS

Throttle Lever

Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.

WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate a Quadricycle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Quadricycle.

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

Electronic Throttle Control

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

FEATURES AND CONTROLS

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

WARNING

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Foot Brake

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 lever.

WARNING

Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

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 46, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope handle tightly.

2. Pull slightly until the starter mechanism engages.

3. Pull the rope abruptly to start the engine.

Extending the recoil starter rope until it stops can cause damage to the recoil assembly.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components.

Handle

Recoil

Starter

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full right position.

NOTE: The handlebars may also be

2. Insert the steering lock key and

3. Remove the key.

NOTE: Place the steering lock keys in

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane of 87. Do not use E-85

fuel.

locked in the full left position.

turn it clockwise.

a safe place. The lock must be replaced if the keys are lost.

Fuel Tank

Cap

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

FEATURES AND CONTROLS

Automatic Transmission 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 P: Park

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage. Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.

Gear

Selector

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

4X4

When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.

NOTE: The override switch allows activation of 4X4 in reverse if the 4X4

switch is on. See page 20.

2X4

When the switch is on 2X4, the vehicle is in two-wheel drive at all times.

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage 4X4 before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when all four of the following conditions occur:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 24 km/h or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the following conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle speed exceeds 24 km/h

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Passenger Seat

Always make sure the passenger seat lock-out is functioning properly before operating with a passenger.

Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always return the seat to the 1-up position for single-rider operation.

Never carry cargo in the rear box when operating the vehicle in the 2-up mode with a passenger.

Seat Conversion

1. Make sure the cargo box dump lever is securely latched.

2. Rotate both operator backrest latches 1/4 turn to release the locks.

3. Tilt the backrest slightly forward.

4. Pull the passenger backrest upward from the bed of the cargo box.

Operator Backrest Latches

(view from front)

Locked

Unlocked

Dump Lever

Passenger

Backrest

FEATURES AND CONTROLS

Passenger Seat

Seat Conversion

5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desired position. Release the latch, making sure it locks into one of the three operating positions.

NOTE: The backrest must be moved out of the lowest position before it can be

6. Lower the operator

7. Test the passenger seat

NOTE: If the lock-out is not working properly, do not allow a passenger to ride

8. To return the vehicle to single-rider

secured in the upright position. The lowest position is for seat storage only. Do not leave the backrest in the lowest position. Always adjust the backrest to one of the three operating positions.

backrest to create the passenger seat. Two

Backrest

Adjustment

Latch

retaining pins under the seat should fit into the two grommets on the seat

Passenger

Seat

base.

lock-out by attempting to release the cargo box dump lever. If the dump lever releases, the seat is not secure. Repeat the setup procedure.

the vehicle. See your Polaris dealer for service.

operation, reverse all steps. Always

Locked

lower the passenger backrest to the lowest position before folding it down into the cargo box. Turn the operator backrest latches 1/4 turn to secure the locks.

FEATURES AND CONTROLS

Instrument Cluster

The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.

Speedometer

Needle

Speedometer

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

when a warning condition exists.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

1. Gear Indicator - This

2. 4X4 Indicator - This

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

6. Fuel Gauge - The segments of the fuel gauge show the level of fuel

7. Check Engine Warning Indicator - This indicator serves two pur-

8. Mode Indicator

have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis.

indicator displays gear

shifter position: H = High Gear

L = Low Gear N = Neutral R = Reverse Gear P = Park

indicator illuminates when the 4X4 switch is

on either ADC 4X4 or 4X4.

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

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.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles or kilometers traveled by the Quadricycle.

Trip Meter Mode

The trip meter records the miles or kilometers traveled by the Quadricycle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be normal because

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

37.

mal point, but the odometer displays without a decimal point.

of changes in humidity, temperature and elevation.

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 movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on. Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

3. Press and hold the mode button until the hour display flashes. Release the button.

4. Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.

5. When the desired hour is displayed, wait approximately four seconds, until the minute display flashes.

6. When the display stops flashing, the mode has been set.

7. Use the same procedure to reset the minutes.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 39.

NOTE: The service interval is programmed at 50 hours at the factory.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.

NOTE: If you scroll past the intended number, press and hold the button until

5. When the desired setting is displayed, wait until the wrench icon

the hours cycle back to zero.

stops flashing. The new service interval is now programmed.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles (MP).

3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs.

See page 42 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in

PARK. Stop the engine. Turn the key switch to the ON position.

2. Turn the key switch off and on three times in less than five seconds. The word “WAIt” will appear on the screen.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.

4. Count the number of times the Check Engine icon flashes.

Example: For the two blink codes 42 and 36, the Check Engine icon will flash 4 times, pause, then flash 2 times (code 42), then pause longer, blink 3 times, pause, and blink 6 times (code 36).

5. A code 61 will signal the end of the sequence. If no blink codes are found, only codes 12 and 61 will appear during the sequence.

NOTE: The word “WAIt” will remain on the screen through this entire process.

Code Definitions

Open Load:

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

the electronic control unit is shorted to a wire at battery voltage.

There is a break in the wires that lead to the item listed in

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink Code

12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 47 IAC Stepper Motor: Open Load 47 IAC Stepper Motor: Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery 52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground 52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery 55 MIL Circuit: Open Load/Short-to-Ground 55 MIL Circuit: Shorted Load/Short-to-Battery 56 Fuel Pump: Open Load/Short-to-Ground 56 Fuel Pump: Shorted Load/Short-to-Battery 58 Fan Circuit: Open Load/Short-to-Ground 58 Fan Circuit: Shorted Load/Short-to-Battery 59 ADC: Open Load/Short-to-Ground 59 ADC: Shorted Load/Short-to-Battery 63 Starter Enable: Open Load/Short-to-Ground 63 Starter Enable: Shorted Load/Short-to-Battery 72 Gear Sensor Signal 73 4X4: Open Load/Short-to-Ground 73 4X4: Shorted Load/Short-to-Battery 74 Rear Differential Enable: Open Load/Short-to-Ground 74 Rear Differential Enable: Shorted Load/Short-to-Battery 61 END SEQUENCE

Failure Description

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

OPERATION

Break-In Period

The break-in period for your new Polaris Quadricycle 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 Quadricycle more than following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 28.

2. Check the engine oil level. See page 74. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Drive slowly. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 45.

6. Pull only light loads.

7. Change the oil and filter at one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

Pre-Ride Checklist

Item Remarks Page

Hand brake/lever travel Ensure proper operation 91

Foot brake Ensure proper operation 91

Brake fluid Ensure proper level 91

Passenger seat lock-out Ensure proper operation 32

Front suspension Inspect, lubricate if necessary 73

Rear suspension Inspect, lubricate if necessary 73

Steering/steering lock Unlock the steering; ensure free oper-

Steering Ensure free operation -

Tires Inspect condition and pressure 96

Wheels/fasteners Inspect, ensure fastener tightness 96

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 28

Coolant level (if applicable) Ensure proper level 86

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 24

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 21

Mirrors Adjust for best side/rear vision 24

Air filter, pre-filter Inspect, clean 98

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

Brake light/taillight Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 84

ation

tric grease when lamp is replaced

protective clothing

101

103

OPERATION

Starting the Engine

WARNING

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 for several minutes before operating.

1. Position the vehicle on a level

surface.

2. Place the transmission in PAR K.

3. Sit on the vehicle.

NOTE: The starter interlock will prevent the engine from starting if the trans-

4. Move the engine stop switch to

NOTE: Do not press the throttle while

mission is in gear and the brake is not engaged.

RUN.

starting the engine.

5. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

6. If the engine does not start, release the starter and wait five seconds.

7. Repeat steps 5 and 6 until the engine starts.

OPERATION

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained.

Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

PVT Operation

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 11 km/h Low

Towing heavy loads Low

Operating in rough or rugged terrain Low

Operating at speeds greater than 11 km/h High

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 18.

2. Perform the pre-ride inspection. See page 45.

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 and allow it to warm up.

7. Apply the brakes.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the brakes.

11. Slowly squeeze the throttle lever toward the handlebar to begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

OPERATION

Turning the Vehicle

1. Before turning, activate a turn signal to alert others of your intentions. 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 while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.

3. Never turn quickly when carrying

a passenger or cargo.

4. Practice making turns at slow speeds before attempting to turn at

faster speeds.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

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 Quadricycle.

Never carry more than one passenger on this 2-up Quadricycle.

1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles.

2. Make sure the passenger is

wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 18.

3. Perform the pre-ride inspec-

tion. See page 45.

4. Convert the seat for passenger

use. See page 32. Make sure the passenger seat lock-out is functioning properly.

5. Place the transmission in PARK.

OPERATION

Driving with a Passenger

6. Mount the vehicle from the left side.

7. After the operator is seated, the passenger should mount the vehicle from the left side.

NOTE: Allow a passenger to ride only in the approved passenger seat with

8. Drive slowly. Control may be more difficult with a passenger on

9. Avoid unexpected or aggressive maneuvers that could cause a pas-

10. Do not cross a hillside with a passenger on board. See page 54.

11. Never secure a passenger to the vehicle or to the operator with a

12. Make sure the passenger understands the importance of "active

both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

board. Allow more time and distance for braking.

senger to fall from the vehicle.

belt, rope or similar device.

riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

OPERATION

Driving Uphill

15° Maximum

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

2. Avoid steep hills (15° maximum).

3. Avoid hills with slippery or loose surfaces.

4. Keep both feet on the footrests.

5. Shift body weight uphill.

6. Drive straight uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

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 passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

4. Use the K-turn to turn around. See page 56.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15°.

>15°

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

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. If operating in 2X4 mode, make sure the differential is locked ().

3. Avoid hills with slippery or loose surfaces.

4. Avoid crossing the sides of steep hills.

5. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside.

6. Shift your weight uphill.

7. Keep your feet on the footrests.

8. Steer slightly into the hill.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

2. Avoid hills with slippery or

loose surfaces.

3. Never drive downhill at high

speed. Slow down.

4. Drive straight downhill.

Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.

5. Shift your weight rearward.

6. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

15° Maximum

OPERATION

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

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.

2.4 m

1. Stop the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake.

8. Slowly release the brake lever and allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill.

NOTE: A passenger should not remount until the vehicle returns to level

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake.

14. Release the foot brake and drive slowly downhill. Control speed

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

ground.

with either the hand or foot brake until the vehicle is on level ground.

>15°

OPERATION

Driving Through Water

Maximum

Depth

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 footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

5. Wet brakes may have reduced stopping ability. Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal.

OPERATION

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 106. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

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 quick, sharp turns.

6. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

7. Never apply the brakes during a skid.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning. Engage 4X4 when the wheels have traction.

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 obstacle.

Always follow the procedures outlined in this manual for operating over obstacles.

OPERATION

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Always block the rear wheels on the downhill side.

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 turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

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.

• Never exceed the stated load capacity for this vehicle.

• Never carry cargo in the rear box when operating the vehicle in the 2-up mode with a passenger.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

• WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low as possible. Carrying a high load raises the center of gravity and creates a less stable operating condition. Reduce load weight when cargo is high. When handling off-centered loads that cannot be centered, secure the load and operate with extra caution.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift and create unstable operating conditions, which could result in loss of control of the vehicle. Always be sure that the cargo bed is lowered and latched before operating the vehicle.

• USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• BALANCE LOADS proportionally between the front rack and cargo bed, but do not exceed the stated load capacity. Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn.

• USE EXTREME CAUTION when applying brakes with a loaded vehicle.

• TOWING is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Always attach a towed load to the hitch point. Avoid towing on inclines.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

OPERATION

Hauling Cargo

Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle.

1. Always load the cargo box with the load as far forward as possible.

2. Slow down.

3. Make sure the cargo box

dump latch is securely latched before loading and operating. Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured.

OPERATION

Hauling Cargo

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road.

Avoid towing on inclines. Do not exceed the maximum capacities when towing. If towing a load,

reduce cargo bed weight by the amount of tongue weight. The combination of cargo bed weight and tongue weight must not exceed the cargo bed capacity.

Maximum Towing Capacities

Maximum Towed Load (Level Ground) 557 kg

Maximum Vertical Hitch Weight 55 kg

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 17 cm. Never install automotive accessories on your Polaris Quadricycle. Always install Polaris-approved (or equivalent) accessories designed for Quadricycle use.

Maximum

17 cm

OPERATION

Hauling Cargo

Dumping Cargo

1. Position the vehicle on a level surface. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Place the transmission in PARK.

3. Dismount the vehicle.

4. Lower the tailgate.

If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible.

5. Pull the cargo box release lever

upward.

6. Lift the front of the cargo box

to dump the cargo.

7. Lower the cargo box. Secure

the release latch.

8. Secure the tailgate.

Dump Box

Release

Latch

Never operate this vehicle with the cargo box in the raised position. The cargo box could close unexpectedly and injure the driver. The rear tires will also catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian ICES-002 and European directives 89/336/EEC and 97/24/EC.

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 34.

Record maintenance and service in the Maintenance Log beginning on page 136.

NOTE: Service and adjustments are important for proper vehicle operation. If

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 indicate 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 the cause or see your dealer.

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

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.

WARNING

Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever - Pre-Ride -

Foot brake - Pre-Ride -

Brake system - Pre-Ride -

Passenger seat lock-out

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant - Daily - Check level daily, change

X ADC fluid - Daily - Check level daily, add as

Headlight/taillight - Daily - Check operation; apply

(whichever comes first)

Hours Calendar Kilometers

ed. See Pre-Ride Checklist on page 45.

-Pre-Ride -

as needed

- Daily - Drain deposits when visible

coolant every 2 years

needed

dielectric grease if replacing lamps

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

Recoil housing - Weekly - Drain water as needed,

Brake pad wear 10 Monthly 160 Inspect periodically

Battery 20 Monthly 320 Check terminals; clean; test

X Demand drive fluid 25 Monthly 400 Inspect level; change yearly X Rear gearcase oil

(if equipped)

X Transmission oil 25 Monthly 400 Inspect level; change yearly XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

X General

lubrication

Shift linkage 50 6 M 800 Inspect, lubricate, adjust

Steering 50 6 M 800 Lubricate

X Front suspension 50 6 M 800 Lubricate X Rear suspension 50 6 M 800 Lubricate

Throttle cable/

ETC switch

E Throttle body

intake duct

Drive belt 50 6 M 800 Inspect; adjust; replace as

Cooling system 50 6 M 1600 Inspect coolant strength

X Engine oil change 100 6 M 1600 Perform a break-in oil change

X Oil filter change 100 6 M 1600 Replace with oil change X Oil tank vent hose

(if equipped)

(whichever comes first)

Hours Calendar Kilometers

- Weekly - Inspect; replace as needed

check often if operating in wet conditions

25 Monthly 400 Inspect level; change yearly

25 Monthly 400 Inspect; clean if needed

- 1 M - Perform a break-in oil change

50 3 M 800 Lubricate all fittings, pivots,

50 6 M 800 Inspect; adjust; lubricate;

50 6 M 800 Inspect duct for proper seal-

100 6 M 1600 Inspect routing, condition

at one month

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Valve clearance 100 12 M 1600 Inspect; adjust

Fuel system 100 12 M 1600 Check for leaks at tank cap,

X Radiator 100 12 M 1600 Inspect; clean external

X Cooling hoses 100 12 M 1600 Inspect for leaks X Engine mounts 100 12 M 1600 Inspect

Exhaust muffler/ pipe

Spark plug 100 12 M 1600 Inspect; replace as needed

X Wiring 100 12 M 1600 Inspect for wear, routing,

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 24 M 3200 Change every two years

ADC fluid 200 H 24 M 2000 (3200) Change every two years

Fuel filter 200 24 M 3200 Replace every 2 years, more

Spark arrestor 300 36 M 4800 Clean out

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Kilometers

lines, filter, pump; replace lines every 2 years

surfaces

100 12 M 1600 Inspect

security; apply dielectric grease to connectors subjected to water, mud, etc.

100 12 M 1600 Inspect; clean; replace worn

100 12 M 1600 Inspect; replace as needed

parts

often under severe use

when parts are replaced

Remarks

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Items not listed in the chart should be lubricated at the General Lubrication interval.

NOTE: The a-arms and upper control arms are lubricated at the factory, and

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only --- See page 88.

Transmission Oil Polaris AGL Synthetic

Demand Drive Fluid (Front Gearcase)

ADC Fluid Polaris ADC Fluid --- See page 84.

Front Prop Shaft Yoke

no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Capacity at

Method

Fluid Change

Synthetic 2W-50

Gearcase Lube

Demand Drive LT Premium Fluid

Polaris Premium U-Joint Lube

2 qt. (1.9 l) See page 74.

32 oz. (948 ml) See page 80.

9.3 oz. (275 ml) See page 82.

--- Grease fittings (3 pumps maximum) every 800 km, before long periods of storage, or after pressure washing or submerging.

Front Prop Shaft Yoke

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil. Never substitute or mix oil brands.

Oil Specifications

Lubricant Capacity Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

1.9 liters 19-23 N-m

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.

MAINTENANCE

Dipstick

7. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

Safe Range

{

Add Oil

8. Reinstall the dipstick.

Safe

MAINTENANCE

Engine Oil

Oil and Filter Change

CAUTION

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Clean the area

around the drain plug.

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

8. Drain the oil.

Drain

Plug

New Sealing Washer

Screen

Fitting

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 74.

MAINTENANCE

Engine Oil

Oil and Filter Change

11. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting.

NOTE: The fitting threads must be

12. Reinstall the screen fitting and

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter.

15. Clean the filter sealing area on the

sealed with LOCTITE PST 505 or PTFE seal tape.

rotate the fitting clockwise a

Alignment Mark

minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.

Using an oil filter wrench, turn the filter counterclockwise to remove it.

crankcase.

16. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.

17. Install the new oil filter. After the filter contacts the crankcase surface, turn it 1/2 turn by hand.

18. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should be clean

and free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to 19 N-m.

MAINTENANCE

Engine Oil

Oil and Filter Change

20. Remove the dipstick.

21. Add 1.9 liters of recommended oil.

NOTE: If the sump is not drained,

22. Reinstall the dipstick.

23. Place the transmission in PARK.

24. Prime the oil pump using the procedure

25. Stop the engine. Check for oil leaks.

add about 1.6 liters initially.

on page 79.

26. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

27. Reinstall the dipstick.

28. Discard used oil and filter properly.

Add Oil

Safe Range

{

Safe

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 vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air. If you do not hear a rush of air, repeat the priming procedure.

Tank

5 cm

Clamp

Pressure

Relief Slit

MAINTENANCE

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil.

See page 128 for the part numbers of Polaris products.

Transmission Oil Recommendations

Lubricant Oil Change

Premium AGL Synthetic

Gearcase Lubricant

Capacity

948 ml 30 N-m 30 N-m

Transmission Oil Level

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level. Add

the recommended oil as needed. Do not overfill.

5. Reinstall the fill plug.

Torque to specification.

Fill Plug

To r q u e

Drain Plug

To r q u e

Oil Level

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. See page 80.

8. Add the recommended oil. See page 80.

9. Reinstall the fill plug. Torque to specification. See page 80.

10. Check for leaks.

11. Discard used oil properly.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Use the recommended fluid. Use of other fluids may

Demand Drive LT

Premium Fluid

275 ml 11-14 N-m 15 N-m

Fill Plug

To r q u e

result in improper operation of components. See page 128 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads.

Fill Level

Drain Plug

Fluid Level

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

Drain Plug

To r q u e

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 specification. See page 82.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

MAINTENANCE

Active Descent Control (ADC) Fluid

The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 128 for the part numbers of Polaris products.

Fluid Level

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 add the

recommended fluid as needed.

NOTE: DO NOT use brake fluid.

6. Maintain the fluid level

between the minimum and maximum marks. Do not overfill.

Brake Fluid

Reservoir

(Black Cap)

ADC Fluid

Reservoir

(Yellow Cap)

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and

bleeder valves (one on each side of the differential).

3. Remove the reservoir cap and diaphragm assembly. Use a shop

towel or suction tool to remove debris from the fluid and reservoir.

NOTE: Debris in the reservoir may result in inadequate bleeding and reduced

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the

9. Reinstall the cap securely. Clean up any drips or spills.

performance of the system.

fluid and trapped air to flow from the fitting. Close the valve when clean fluid begins to flow. Repeat this step for the remaining valve.

minimum and maximum marks. Make sure the reservoir is free of debris.

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/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 128 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

Recovery Bottle Coolant

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Add coolant as needed.

NOTE: Check the coolant level in the radiator any

1. Check the coolant level when the

2. Remove the left side panel. See page

NOTE: Maintain the coolant level between

freeze protection required in your area.

time the recovery bottle has run dry. Add coolant as needed.

fluid is cool.

94.

the minimum and maximum marks on the bottle (when the fluid is cool).

3. View the coolant level.

4. Add coolant as needed.

5. Reinstall the side panel.

MAINTENANCE

Cooling System

Radiator Coolant

WARNING

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 radiator filler neck.

5. Reinstall the pressure cap.

6. Secure the access door and

box cover.

NOTE: Use of a non-standard

pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

WARNING

Operating the Quadricycle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the Quadricycle with spongyfeeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 128 for the part numbers of Polaris products.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

MAINTENANCE

Indicator

Master

Cylinder

Window

1. Position the vehicle on a level surface. Make sure the handlebars are straight.

2. View the fluid level

through the indicator window (eye) on the top of the master cylinder.

NOTE: The eye will appear dark

when the fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended fluid as needed. Do not overfill.

Full

Low

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 add the

recommended fluid as needed.

NOTE: DO NOT use ADC fluid.

6. Maintain the fluid level

between the minimum and maximum marks. Do not overfill.

Brake Fluid

Reservoir

(Black Cap)

ADC Fluid

Reservoir

(Yellow Cap)

Maximum Minimum

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by applying 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 operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 88.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface condition

of the disc.

1 mm

MAINTENANCE

Toe Alignment

WARNING

Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire.

NOTE: If available, you may

use a long straightedge instead of string.

4. Measure the distance

from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

NOTE: If you discover improper alignment, see your Polaris dealer for service.

Stand

String

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.

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height.

NOTE: Be sure the handlebars do not

4. Torque the front two bolts to 14-17

contact the gas tank or any other part of the machine when turned fully to the left or right.

N-m, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear of the clamp blocks.

14-17 N-m

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.

Adjuster

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.

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

Screws

Rivets

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.

Boot

3. Loosen the adjuster lock nut.

MAINTENANCE

Lock Nut

Adjuster

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever.

NOTE: Move the throttle lever

back and forth while adjusting.

1.6-3.2 mm

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it over the cable adjuster to its original position.

NOTE: Engine RPM should not increase when steering is turned full left or

right. Readjust cable freeplay if this occurs.

MAINTENANCE

Tires

Refer to the specifications section beginning on page 126 for recommended tire type, size and pressure.

WARNING

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 decal on your vehicle and in the specifications section of the owner's manual.

• Use only original equipment size and type when replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

3 mm

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for maintenance service.

Nut Type Nut Torque

Lug Nut 122 Nm

2-Piece Flange Nut 37 Nm

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 frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger

tight.

9. Lower the vehicle to the

ground.

10. Torque the wheel nuts to

specification. See torque chart on page 96.

MAINTENANCE

Air Filter

Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 69.

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. Remove the air

box cover.

6. Loosen the hose

clamp.

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry.

NOTE: Replace the filter if needed.

10. Reverse the steps to reinstall all components.

Pre-Filter

Main Filter

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 94.

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 direction of the arrow to check for clogging. Replace a damaged or clogged filter.

4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter and hose clamps.

NOTE: The filter is effective with the arrow pointing in either direction.

Breather Filter

Operation of your vehicle without a breather filter can cause engine damage.

Polaris Sportsman 9921848 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual