Instruction/ maintenance manual of the product Sportsman 9921822 Polaris
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A card containi ng important A TV safety informa tion should be attached to the owner's man ual on the next page. If you canno t locate th is card, or if it has been removed, plea se call 1-8 00-342- 3764 for assistance.
1 WELCOME Thank you for purch asin g a Polaris vehicl e, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products.
2 POLARIS and POLARIS THE W A Y OUT are regist ered tradem arks of Polari s Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potentia l personal injury ha za rd.
5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate . This vehicle ha ndles differently than other vehicles, such as motorcycles and cars.
6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and mating it wi th one of your ex isting keys.
7 SAFETY Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchase d your new A TV , yo ur dealer instructed you on the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV .
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the ch ance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.
10 SAFETY Safety W arnings Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual.
11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive u nder certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventil ated area.
12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e withou t wearing an approved helmet and protective eyewe ar increases the risk of a serious inj uries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield).
13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV and co uld result in loss of control and accident or overturn.
14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to co ntrol the ve hicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.
15 SAFETY Safety W arnings Descending Hill s Impr oper ly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hi ll s as de scri b e d in the own e r 's manual. NOTE: A special techn ique is required when braking while traveling do wn- hill.
16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or impr operl y dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill.
17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain.
18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could resul t in a collision with an obstacle or person. Always follow prope r op erating procedures as outli ned in this manual. See page 55. Before shifting into reverse gear , always check for obstacles or people behind the A TV .
19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obst acles. Avoid operating over large obstacles such as rocks and fallen trees.
20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cau se changes in handling, which could cause loss of contro l or an acciden t. • Never exceed the stated load capa city for this A TV . • Cargo should b e properl y distributed and securely attached.
21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A T V can result in a n accident. After any overturn or accident, have a qual ified service dealer in spect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems.
22 SAFETY Safety Labels and Locations W arning labels have b een placed on the ve hicle for your protec tio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the labe ls on your vehicle, always read and follow the instructio ns of the labels on the vehicle.
23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 de grees 25 ° . T o prevent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds.
24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 T ire Pressure/Load W arning W ARNIN G Improper tire pressure or overlo ading ca n cause loss of control.
25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are unde r the age of 16 increases your chan ce of severe injury or d eath. NEVER operate this A TV if you are under age 16. 7175374 Rack W arning, Front and Rear W ARNING • DO NOT TO W FROM RACK OR BUMPER.
26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse sp eed limit er system . T o gain additional wheel speed while backing, release the throttle and depress the override button.
27 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lig h ts on and of f. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. All Wheel Drive Switch See page 35 for all wheel drive information.
28 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, whi ch could cause an accident. Neve r operat e the A TV with a spongy-feeling bra k e lever . Always contact your dealer for service before operati ng th e vehicle.
29 FEA TURES AND CONTROLS Parking Brake Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever .
30 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous in jury or death. Never ba ck down a hill. Use caution when applying the a uxiliary bra ke.
31 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may cause brake drag or brake l ock-up, which co uld result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid.
32 FEA TURES AND CONTROLS Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder . Do not over- fill. 1. Position the vehicle on a level surface.
33 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Always refuel with the engine stopped, and outdoo rs or in a well ventilated area.
34 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehi- cle. H: High Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .
35 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The Al l Wheel Driv e syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive.
36 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in mile s as well as hours of operation.
37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position.
38 OPERA TION Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’ s manual.
39 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 65. Add oil if neces- sary to maintain the level between the safe and add marks.
40 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this ve hicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e.
41 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ri de. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a local riding club or local officials.
42 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before ea ch use to make sure it's in safe operating condition.
43 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parkin g brake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged.
44 OPERA TION S t arting the Engine 9. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the en gin e starts. NOTICE: Operating the vehicle immediate ly after starting could cause engine damage.
45 OPERA TION Driving Procedures 1. W ear a helmet and eye protection.See page 8. 2. Sit uprigh t with both feet on th e footrests and bo th hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5.
46 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction sl ightly .
47 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trai ls or loose gravel, or during freezin g weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas.
48 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of c ontrol or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill.
49 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proc edure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidab le , follow these precautions: 1.
50 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum) . 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control.
51 OPERA TION Parking on an Incline A void parking on an in cl ine if po ss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Always block the rear wh eels on the downhil l side.
52 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping b ody weight uphill. 2. Leave the transmission in forward and shut off the engine.
53 OPERA TION Driving Through W ater Y our A TV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures when operating through water: 1. Determine water depths and cu rren t before entering water .
54 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacle s: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches.
55 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or people behind the vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turnin g at sharp angles.
56 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e handling and may cause loss of control or brake instability , which can result in serious injury or death.
57 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A TV on warning labels and in the specifications section of this manual. Carg o weight should b e evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
58 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
59 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma in tenance ch art.
60 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result i n component failure an d cause an accident, which ma y result in se rious injury o r death. Always have an authorize d Po la ris dealer perform these services.
61 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - W eekly - Inspect; replace as needed X Q B.
62 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
63 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 59. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PL US P erformance Synthetic 2W -50 See page 64.
64 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil.
65 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the left front tire. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parkin g brake. 4. Clean away all dirt and debris on the oil tank or in the wheel well area.
66 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beg inning on page 5 9.
67 MAINTENANCE Oil and Filter Change 1 1. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.
68 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 59. Maintain the oil level at the bottom of the fill pl ug hole. See page 109 for the part numbers of Polaris products.
69 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill.
70 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan u nder the gearcase. 6. Remove the drain plug.
71 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 59. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper opera tion o f compo- nents.
72 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recomme nded oil as needed to bring the level to the bottom of the fill hole threads.
73 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase.
74 MAINTENANCE Cooling System The engin e coolan t level is controlled, or maintai ned, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
75 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair .
76 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition.
77 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result from improper toe alig nment and adjustment.
78 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be che cked periodica lly for loose nuts and bo lts. If loose nuts and bolts are fo und, see your Polaris dealer for service before ope rating the vehicl e. Side Panel Removal 1.
79 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr ope rly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and cou ld cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle.
80 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. Loosen the wheel nuts slightly . W ARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris deale r .
81 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the wheel on the wheel hub with the valve stem toward the ou tside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the vehi cle to the grou nd.
82 MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear . 2. Lock the parkin g brake. 3. Remove the seat. 4. Release the air box cover clips, and remove the air box cover . 5. Loosen the clamp and remove the filter .
83 MAINTENANCE Breather Filter/Hose 1. Remove the left side panel. See page 78. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for cloggin g.
84 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.
85 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps pro mptly . Always make sure lights are adjusted properly for best visibility .
86 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifications section begi nni ng o n pag e 1 14 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs t o specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
87 MAINTENANCE Spar k P l ug s S p ark Plug Condition Normal Spar k Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
88 MAINTENANCE V ehicle Immersion If your vehicle bec om es immersed, majo r engine damag e ca n result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A TV to a de aler before starting it, follow the steps outlined below .
89 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warni ngs while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the area. Wear eye protectio n and leather work gloves.
90 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failure ma y occur at a high speed. The PVT system ha s been precision balanced.
91 MAINTENANCE P VT System P VT Drying There m ay be so me ins tances when water is accidently ingested into the PVT system. Use the following instructions to dry it out befo re operating. 1. Move the vehicle out of the water . 2. Remove the P VT drain plug.
92 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removi ng the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last.
93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parkin g brake. 3. Remove the sp lash shield behind the right front tire. 4. Remove the left side panel to access the battery hold- down bracket. Remove the screw at the bottom rear of the bracket and move the bracket aside.
94 MAINTENANCE Battery Battery Inst allatio n Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinde r vehicle performance. Follow the battery charging instructions on page 96 before installing the battery .
95 MAINTENANCE Battery Batter y S tor age Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s t orag e and recha r ge as needed to maintain a full charge.
96 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prev ent damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 93. 2. Char ge the battery with a char ging output no lar ger than 1/10 of the battery’ s amp/hr rating.
97 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Measure battery voltage at the starting so lenoi d (near the radiator cap) under the front storage cover . Check the battery voltage with a voltmeter or multimeter .
98 MAINTENANCE Cleaning and S torage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. NOTICE: High water pre ssure may damag e components. Polaris recommend s washing the vehicle by hand or with a g arden hose, using mild soap.
99 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (n ot recommended), exercise extreme caution.
100 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
101 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S tarting the engine durin g the storage perio d will di sturb the protective film created by fogging and damage coul d occur . Never start the engine during the stora ge peri od. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended.
102 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in th e Periodic Maintenance Chart beg inning on page 5 9. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1.
103 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 59. Battery Storage See pages 95-96 for storage and charging procedures.
104 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parkin g brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat.
105 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. S pring Adjustment s The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension.
106 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adjustment of th e hand leba rs or incorrect torquing of the adjuster block tightenin g bolts can caus e li mited steeri ng or loosening of the handlebars, resulti ng in lo ss of control and serious injury or death.
107 ADJUSTMENTS Carburetor Y our Polaris A TV is cali brated at the factor y for optimal performa nce at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F .
108 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and slide it far enough to expose th e end of the inline cable adjuster .
109 POLARIS PRODUCTS Pa r t Number Desc ription Engine L ubricant 2870791 Fogging Oil (12 oz . Aerosol) 2876244 PS-4 PLUS P erformance Syn thetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Syn thetic 2W -50 4-Cycle Oil (gal .) Gearcase / T ra nsmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.
110 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range (if equipped). Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 52).
111 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Rechar ge the battery to 12.
112 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recomme nded fuel Incorrect ignition t.
113 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged f.
114 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 400 HO 4X4 Maximum W eight Capacity 385 lbs. (175 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 598 lbs. (271 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts.
115 SPECIFICA TIONS Jetting Chart Clutching Ch art Sportsman 400 HO 4X4 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (H/N/R) Drive Ratio, Fron t 3 .6:1 Drive Ratio, Final 15.18:1 T ires/Pressure Front 24x8-12 / 5 psi (34.
116 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship . Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
117 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANT IES AND REMEDIE S The Polaris l imited warrant y excludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
118 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY .
119 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA - TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries.
120 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied.
121 W ARRANTY U.S.A. EP A Emission s Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions lim it ed warranty is in addition to the Polaris st andard limited warrant y for this vehicle.
122 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
123 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS.
An important point after buying a device Polaris Sportsman 9921822 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris Sportsman 9921822 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris Sportsman 9921822 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris Sportsman 9921822 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris Sportsman 9921822 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris Sportsman 9921822, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris Sportsman 9921822.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris Sportsman 9921822. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris Sportsman 9921822 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
