Polaris Sportsman 9922242 User Manual

Pantone 426COwner's Manualfor Maintenance and SafetyRead this manual carefully. It contains important safety information.This is an adult vehicle

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

96MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electroly

97MAINTENANCEBatteryBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVol

98MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend the

99MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

100MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

101MAINTENANCECleaning and StorageStorage TipsNOTICE: Starting the engine during the storage period will disturb the protective film created by foggin

102MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beg

103MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

104MAINTENANCETransporting the VehicleFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in gear.3. Lo

105ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Spring AdjustmentsThe front and rear shock absorber springs are adjustable. Ro

7SAFETYSafety TrainingATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the

106ADJUSTMENTSHandlebarsThe handlebars can be adjusted for rider preference.WARNING! Improper adjustment of the handlebars or incorrect torquing of th

107ADJUSTMENTSCarburetorYour Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) an

108ADJUSTMENTSThrottle Cable FreeplayAdjust throttle cable freeplay at the handlebar.1. Locate the throttle cable adjuster at the handlebar.2. Squeeze

109POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

110TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range (if equipped).Starting o

111TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionBlown fuse Replace fuseLow batt

112TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

113TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

114SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman 300Maximum Weight Capacity 385 lbs. (175 kg) (includes weight of operator, cargo and acces

115SPECIFICATIONSJetting ChartClutching ChartSportsman 300Drive Ratio, Front 3.6:1Drive Ratio, Final 15.18:1Tires/Pressure, Standard models Front 22x7

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

116DECLARATION OF CONFORMITYPolaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500We, Polaris Industries Inc., declare th

117WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

118WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

119WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESThis warranty also excludes failures resulting from improper lubrication; improper engine timing; imp

120WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

121WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

122WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen, to be kept a

123WARRANTYU.S.A. EPA Emissions Limited WarrantyThis emissions limited warranty is in addition to the Polaris standard limited warranty for your vehic

124WARRANTYU.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris,

125MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

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

126MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

127INDEXAAccessories . . . . . . . . . . . . . . . . . . . 103Air Filter . . . . . . . . . . . . . . . . . . . . . . 82All Wheel Drive Switch . . .

128INDEXHHandlebar Adjustment. . . . . . . . . . 106Hauling Cargo . . . . . . . . . . . . . . . 56-57Headlamp Replacement . . . . . . . . . . 84H

129INDEXSStorage . . . . . . . . . . . . . . . . . . . 98-103SwitchesAWD Switch. . . . . . . . . . . . 27, 36Engine Stop Switch. . . . . . . . . .

10SAFETYSafety WarningsFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serio

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

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

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

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

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

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 vehicle for your protection. Read and follow the instructions on each label

23SAFETYSafety Labels and LocationsDiscretionary WarningWARNING• Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on

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

25SAFETYSafety Labels and LocationsAge 16 WarningWARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or de

The text is printed on 100% recycled with 40% post-consumer waste (PCW).

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

27FEATURES AND CONTROLSSwitchesHeadlight SwitchUse the headlight switch to turn the lights on and off. The key must be in the ON position and the engi

28FEATURES AND CONTROLSBrake LeverOperating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never oper

29FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in gear.2. Squeeze and release the brake lever two or three tim

30FEATURES AND CONTROLSAuxiliary Foot BrakeAggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could resu

31FEATURES AND CONTROLSBrake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brak

32FEATURES AND CONTROLSBrake FluidHand BrakeThe master cylinder is located on the left handlebar. Main-tain the fluid level 1/4" (6.3 mm) below t

33FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine starting procedure on page 44 for correct choke and throt

34FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle. H: High GearN:

35FEATURES AND CONTROLSRecoil StarterIf the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 44

WARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER operate:S without proper training or instruction.S at speeds too fast for your

36FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemThe All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is i

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

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

39OPERATIONFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or

40OPERATIONBreak-In PeriodEngine and Drivetrain Break-in1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever han

41OPERATIONSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 7.2. Do not allow anyone under

42OPERATIONKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in

43OPERATIONPre-Ride ChecklistFailure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accid

44OPERATIONStarting the Engine1. Position the vehicle on a level surface outdoors or in a well-venti-lated area. 2. Place the transmission in neutral.

45OPERATIONStarting the Engine9. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds,

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

46OPERATIONDriving 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

47OPERATIONTurning the VehicleYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the whe

48OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

49OPERATIONDriving UphillBraking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or

50OPERATIONDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

51OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Avoid steep hills (25° maximum).2. Shift body weight uphill.3. Drive str

52OPERATIONTurning 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.

53OPERATIONDriving Through WaterYour ATV can operate through water with a maxi-mum recommended depth equal to the bottom of the footrests. Follow thes

54OPERATIONDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2

55OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

2POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc.Copyright 2009 Polaris Sales Inc. All information contained wi

56OPERATIONHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or bra

57OPERATIONHauling CargoNever exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual.C

58OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

59EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

60MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

61MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

62MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

63MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)X General lubrication50 H 3 M 50

64MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related ServiceQ Have an

65MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 60. It

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

66MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

67MAINTENANCEEngine OilOil LevelThe oil dipstick is located behind the recoil on the right side of the ATV.1. Position the vehicle on a level surface.

68MAINTENANCEOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. A

69MAINTENANCEOil and Filter Change11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it.12

70MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag

71MAINTENANCETransmission OilOil Check1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the parking brake.4. Remove

72MAINTENANCETransmission OilOil Change1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the parking brake.4. Remov

73MAINTENANCEFront Gearcase (Demand Drive) FluidAlways check and change the demand drive fluid at the inter-vals outlined in the Periodic Maintenance

74MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Check1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the pa

75MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Change1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the p

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

76MAINTENANCEBrakesThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary

77MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

78MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are fo

79MAINTENANCETiresOperating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle

80MAINTENANCETiresWheel Removal1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the parking brake.4. Loosen the wh

81MAINTENANCETiresWheel Installation1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire poi

82MAINTENANCEAir Filter/Breather Filter1. Position the vehicle on a level surface.2. Place the transmission in gear.3. Lock the parking brake.4. Remov

83MAINTENANCELightsHeadlight Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the ad

84MAINTENANCELightsPoor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. C

85MAINTENANCERecoil HousingAlways drain the recoil housing after operating the vehicle in wet condi-tions. Drain the housing before storing the vehicl

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

86MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 114 for the recom-mended spark plug type and g

87MAINTENANCESpark PlugsSpark Plug Inspection4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap

88MAINTENANCEVehicle ImmersionIf your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the ve

89MAINTENANCESpark ArrestorFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never ru

90MAINTENANCEPVT SystemFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the

91MAINTENANCEPVT SystemPVT DryingThere may be some instances when water is accidently ingested into the PVT system. Use the following instructions to

92MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

93MAINTENANCEBatteryBattery Removal1. Place the transmission in gear.2. Lock the parking brake.3. Open the front cover.4. Disconnect the battery hold-

94MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It c

95MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure