Polaris Sportsman 9921828 Manuale Utente

7SAFETYSafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized

97MAINTENANCESpark PlugsSpark Plug InspectionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion depos

98MAINTENANCEVehicle ImmersionIf your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the ve

99MAINTENANCESpark ArrestorFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never ru

100MAINTENANCEPVT SystemFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of th

101MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed in

102MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

103MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

104MAINTENANCEBatteryBattery Removal1. Disconnect the battery hold-down strap.2. Remove the battery cover.3. On conventional batteries, remove the bat

105MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

106MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

8SAFETYSafe Riding GearAlways wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.He

107MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

108MAINTENANCEBatteryBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVo

109MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

110MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

111MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

112MAINTENANCECleaning and StorageStorage TipsNOTICE: Starting the engine during the storage period will disturb the protective film created by foggin

113MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Ch

114MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

115MAINTENANCETransporting the ATVFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in PARK.3. Lock t

116ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Rear SpringThe rear shock absorber spring is adjusted by rotating the adjuster

9SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sha

117ADJUSTMENTSHandlebarsThe handlebars can be adjusted for rider preference.WARNING! Improper adjustment of the handlebars or incorrect torquing of th

118ADJUSTMENTSThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris deal

119TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

120TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

121TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

122TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

123POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

124SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman 500 EFIMaximum Weight Capacity 485 lbs. (220 kg) Fuel Capacity 4.13 gal. (15.6 l)Engine Oi

125SPECIFICATIONSClutching*EBS models require no helix/spring adjustmentSportsman 500 EFIShift Type Side Lever (H/L/N/R/P)Gear Reduction, Low 23.91:1G

126WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

10SAFETYFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or de

127WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

128WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

129WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

130WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

131WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

132MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

133MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

11SAFETYSafety WarningsHandling GasolineGasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve

12SAFETYSafety WarningsProtective ApparelRiding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a seri

13SAFETYSafety WarningsOperating on PavementOperating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely

14SAFETYSafety WarningsPhysical Control of the ATVRemoving a hand from the handlebars or feet from the footrests during operation can reduce your abil

15SAFETYSafety WarningsDescending Hills ImproperlyImproperly descending a hill could cause loss of control or overturn.• Always follow proper procedur

16SAFETYSafety WarningsStalling While Climbing a HillStalling, rolling backwards or improperly dismounting while climbing a hill could cause an overtu

2

17SAFETYSafety WarningsOperating on Slippery TerrainFailure to use extra caution when operating on excessively rough, slippery or loose terrain could

18SAFETYSafety WarningsOperating Improperly in ReverseImproperly operating in reverse could result in a collision with an obstacle or person. Always f

19SAFETYSafety WarningsOperating Over ObstaclesImproperly operating over obstacles could cause loss of control or overturn.Before operating in a new a

20SAFETYSafety WarningsImproper Cargo LoadingOverloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause

21SAFETYSafety WarningsOperating a Damaged ATVOperating a damaged ATV can result in an accident. After any overturn or accident, have a qualified serv

22SAFETYSafety Labels and LocationsWarning labels have been placed on the ATV for your protection. Read and follow the instructions of the labels on t

23SAFETYSafety Labels and LocationsTire Pressure/Load WarningWARNINGImproper tire pressure or overloading can cause loss of control. Loss of control c

24SAFETYSafety Labels and Locations“No Passenger” WarningWARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE

25SAFETYSafety Labels and LocationsClutch Cover WarningWARNING• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate

26FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchThis vehicle is equipped with a reverse speed limiter system.To gain additional power while

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or

27FEATURES AND CONTROLSSwitchesEngine Stop SwitchMove the stop switch either left or right to the OFF position to stop the engine quickly. The engine

28FEATURES AND CONTROLSThrottle LeverOperating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or

29FEATURES AND CONTROLSBrake LeverOperating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never oper

30FEATURES AND CONTROLSMaster Cylinder/Brake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an acciden

31FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in PARK.2. Squeeze and release the brake lever two or three tim

32FEATURES AND CONTROLSAuxiliary Foot BrakeAggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could resu

33FEATURES AND CONTROLSFuel Tank CapRemove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump

34FEATURES AND CONTROLSAll Wheel Drive SystemThe All Wheel Drive system is controlled by the 4X4 switch.ADC 4X4 ModeWhen the switch is on ADC 4X4, the

35FEATURES AND CONTROLSAll Wheel Drive System Engaging 4X4The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle&a

36FEATURES AND CONTROLSActive Descent Control (ADC) SystemThe ADC system allows engine braking to all four wheels when the vehicle descends a hill or

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURES AND CONTROLSInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addi

38FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

39FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the MODE button to toggle through the mode options. The reverse ove

40FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

41FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

42FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

43FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesThe EFI diagnostic mode is for informational purposes only. Please s

44FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesCode DefinitionsOpen Load: There is a break in the wires that lead t

45FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesBlink CodeFailure Description12 BEGIN SEQUENCE22 Throttle Position S

46OPERATIONFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2008 Polaris Sales Inc. All information contained with

47OPERATIONBreak-In PeriodEngine and Drivetrain Break-in1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever han

48OPERATIONPre-Ride ChecklistFailure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accid

49OPERATIONSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 7.2. Do not allow anyone under

50OPERATIONKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in

51OPERATIONStarting the Engine1. Position the vehicle on a level surface outdoors or in a well-venti-lated area. 2. Place the transmission in PARK.3.

52OPERATIONDriving Procedures1. Wear a helmet and eye protection. See page 8.2. Sit upright with both feet on the footrests and both hands on the hand

53OPERATIONTurning the VehicleYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the whe

54OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

55OPERATIONDriving UphillBraking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or

56OPERATIONDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . .

57OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a h

58OPERATIONTurning Around on a Hill (K-Turn)If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.1.

59OPERATIONDriving Through WaterYour ATV can operate through water with a maximum recom-mended depth equal to the bot-tom of the footrests. Follow the

60OPERATIONDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2

61OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

62OPERATIONHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or bra

63OPERATIONHauling CargoNever exceed the weight capac-ities specified for your ATV on warning labels and in the speci-fications section of this manual

64OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

65EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

66MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

4INTRODUCTIONThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sy

67MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

68MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

69MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)X General lubrication50 H 3 M 50

70MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related ServiceQ Have an

71MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 66. It

72MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

73MAINTENANCEEngine OilOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on

74MAINTENANCEEngine OilOil and Filter Change10. Reinstall the screen fitting and rotate the fitting clockwise a mini-mum of 2 1/2 turns into the tank

75MAINTENANCEEngine OilOil and Filter Change17. Reinstall the drain plug. The sealing surfaces on the drain plug and crankcase should be clean and fre

76MAINTENANCEEngine OilOil and Filter ChangeOil Pump PrimingThis priming procedure must be performed whenever the oil hose connection between the oil

5INTRODUCTIONFailure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a

77MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag

78MAINTENANCETransmission OilOil Change1. Remove the fill plug.2. Place a drain pan under the gearcase.3. Remove the drain plug. Allow the oil to drai

79MAINTENANCEFront Gearcase (Demand Drive) FluidAlways check and change the demand drive fluid at the intervals out-lined in the Periodic Maintenance

80MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Check1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level. 2.

81MAINTENANCEActive Descent Control (ADC) FluidTwo fluid levels must be maintained on your vehicle, the demand drive fluid and the ADC fluid. See page

82MAINTENANCEActive Descent Control (ADC) FluidFluid Change1. Position the vehicle on a level surface. Before performing the fluid change, allow the v

83MAINTENANCECooling SystemThe engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recov

84MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain t

85MAINTENANCEBrakesHand BrakeThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The

86MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

6INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

87MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are fo

88MAINTENANCETiresOperating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle

89MAINTENANCETiresWheel Installation1. Place the transmission in PARK.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem towa

90MAINTENANCEAir Filter1. Remove the seat. Release the air box cover clips, and remove the air box cover.2. Loosen the clamp and remove the filter.3.

91MAINTENANCEFuse ReplacementIf the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locat

92MAINTENANCELightsPoor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. C

93MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustm

94MAINTENANCELightsHeadlight Housing Replacement1. Remove the two screws on the lower front corners of the headlight pod.2. Lift the pod slightly whil

95MAINTENANCELightsLower Headlamp Replacement1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the he

96MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 124 for the recom-mended spark plug type and g