Polaris Sportsman 9920629 Bedienungsanleitung

7SAFETYSafety Decals and LocationsDiscretionary WarningWARNING• Never operate this ATV on HILLS steeper than 25 degrees 25°. To p r e -vent flip-ov

97MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustm

98MAINTENANCELightsHeadlight Housing Replacement1. Remove the two screws on the lower front corners of the headlight pod.2. Lift the pod slightly whil

99MAINTENANCELightsLower Headlamp Replacement1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the he

100MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 128 for the recom-mended spark plug type and

101MAINTENANCESpark PlugsSpark Plug InspectionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion depo

102MAINTENANCEVehicle Immersion1. If it's impossible to take your ATV to a dealer before starting it, fol-low the steps outlined below.2. Move th

103MAINTENANCESpark ArrestorUse the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.1. Remove the arrestor

104MAINTENANCEPVT SystemWARNINGFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any componen

105MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed in

106MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

8SAFETYSafety Decals and Locations“No Passenger” WarningWARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE I

107MAINTENANCEBatteryYour ATV may have either a sealed battery, which requires little mainte-nance, or a conventional battery. A sealed battery can be

108MAINTENANCEBatteryBattery Removal1. Disconnect the battery hold-down strap.2. Remove the battery cover.3. On conventional batteries, remove the bat

109MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

110MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

111MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

112MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after the end of charging.State of Ch

113MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

114MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

115MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

116MAINTENANCECleaning and StorageStorage TipsClean the ExteriorMake any necessary repairs and clean the vehicle as recommended. See page 113.Stabiliz

9SAFETYSafety Decals and LocationsClutch Cover WarningWARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not o

117MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Ch

118MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

119MAINTENANCETransporting the ATVFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in PARK.3. Lock t

120ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Rear SpringThe rear shock absorber spring is adjusted by rotating the adjuster

121ADJUSTMENTSCarburetorYour Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) an

122ADJUSTMENTSThrottle Cable FreeplayAdjust throttle cable freeplay at the handlebar.1. Locate the throttle cable adjuster at the handlebar.2. Squeeze

123TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

124TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionTripped circuit breaker Reset t

125TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

126TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

10SAFETYSafe Riding GearAlways wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.H

127POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (q

128SPECIFICATIONSSportsman 450Gross Vehicle Weight 1200 lbs. (544 kg)Fuel Capacity 4.25 gal. (16 l)Engine Oil Capacity 2 qts. (1.9 l)Coolant Capacity

129SPECIFICATIONSJetting ChartClutching ChartSportsman 450Shift Type Side Lever (H/L/N/R/P)Gear Reduction, Low 23.91:1Gear Reduction, Reverse 16.30:1G

130WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

131WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

132WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

133WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

134WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

135WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

136MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

11SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sh

137MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

138INDEXAAccessories . . . . . . . . . . . . . . . . . . 118Active Descent Control Fluid . . . 86-87Active Descent Control System. . . . 45ADC

139INDEXGGear Selector. . . . . . . . . . . . . . . . . . . 42Gloves . . . . . . . . . . . . . . . . . . . . . . . . 11HHand Brake . . . . . . . . .

140INDEXSSpark Arrestor . . . . . . . . . . . . . . . . 103Spark Plug Inspection . . . . . . . 100-101Spark Plug Recommendations. . . . 100Spark

12SAFETYOperator SafetyAge RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.WARNINGFailure

13SAFETYOperator SafetySafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you o

14SAFETYOperator SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these wo

15SAFETYOperator Safety• Read this manual and all labels carefully, and follow the operating procedures described.• Never operate an ATV without prope

16SAFETYOperator Safety• Always travel slowly and use extra caution when operating on unfa-miliar terrain. Be alert to changing terrain conditions.• N

17SAFETYOperator Safety• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fa

18SAFETYOperator SafetyFOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, vi

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increase

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying a passenger greatly reduces the operator's a

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with anothe

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs co

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENAttempting stunts increases the chance of an

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrests during operation.WHAT CAN HAPPENRemoving e

25SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAP

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CAN HAPPENThe vehicle may overturn.HOW TO AVOID THE HAZARDNeve

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

27SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or

28SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle c

29SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control

30SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of tra

31SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV with improper tires, or with improper or uneven tire pressure.WHAT CAN HAPPENUse of i

32SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause

33SAFETYOperator SafetyWARNINGOperating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a q

34FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchThis vehicle is equipped with a reverse speed limiter system.To gain additional power while

35FEATURES AND CONTROLSSwitchesEngine Stop SwitchMove the stop switch either left or right to the OFF position to stop the engine quickly. The engine

36FEATURES AND CONTROLSThrottle LeverEngine speed and vehicle move-ment are controlled by pressing the throttle lever. The throttle lever is spring lo

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 CONTROLSBrake LeverSqueeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti

38FEATURES AND CONTROLSMaster Cylinder/Brake FluidCheck the brake fluid in the master cylinder before each ride. The fluid level can be seen through a

39FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in PARK.2. Squeeze and release the brake lever two or three tim

40FEATURES AND CONTROLSAuxiliary Foot BrakeThe auxiliary brake system is intended to be used as a backup for the main brake system. Should the main sy

41FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throt

42FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle. H: High GearL:

43FEATURES AND CONTROLSRecoil StarterIf the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 55

44FEATURES AND CONTROLSAll Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is

45FEATURES AND CONTROLSActive Descent Control (ADC) SystemThe ADC system (if equipped) allows engine braking to all four wheels when the vehicle desce

46FEATURES AND CONTROLSInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The ins

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2006 Polaris Sales Inc. All information contained with

47FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

48FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the MODE button to toggle through the mode options. The reverse ove

49FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

50FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

51FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

52OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling g

53OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two

54OPERATIONPre-Ride ChecklistWARNINGIf a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicl

55OPERATIONStarting the Engine1. Position the vehicle on a level surface.2. Place the transmission in PARK.3. Lock the parking brake.NOTE: The starter

56OPERATIONStarting the Engine8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds,

3TABLE OF CONTENTSKnow Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57OPERATIONCold Weather OperationIf the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of

58OPERATIONHauling CargoYour ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning

59OPERATIONHauling CargoWARNINGOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control

60OPERATIONDriving SafelyDriving Procedures1. Wear protective riding gear. See page 10.2. Sit upright with both feet on the footrests and both hands o

61OPERATIONDriving SafelyTurning the VehicleYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This mean

62OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freez-ing weat

63OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. If your ATV is equipped with Active Descent Control, alw

64OPERATIONDriving SafelyDriving on a Sidehill (Sidehilling)Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a

65OPERATIONDriving SafelyDriving DownhillWhen driving downhill, follow these precautions:1. If your ATV is equipped with Active Descent Control, alway

66OPERATIONDriving SafelyTurning 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

4

67OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through water with a maximum recom-mended depth equal to the bot-tom of the footres

68OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for ha

69OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehic

70OPERATIONDriving SafelyParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the

71EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

72MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

73MAINTENANCEPeriodic Maintenance ChartMaintenance Chart KeyX Perform these operations more often for vehicles subjected to severe use.E Emission-rel

74MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

75MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)X General lubrication50 H 3 M 50

76MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related ServiceQ Have an

5KNOW YOUR VEHICLEAs the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our enviro

77MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Ite

78MAINTENANCEEngine OilOil RecommendationsPolaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle e

79MAINTENANCEEngine OilOil LevelAccess the oil dipstick and fill tube from the left side of the ATV.NOTE: A rising oil level between checks in cool we

80MAINTENANCEOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. A

81MAINTENANCEOil and Filter Change12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove

82MAINTENANCEOil and Filter ChangeOil Pump PrimingThis priming procedure must be performed whenever the oil hose connection between the oil tank and p

83MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag

84MAINTENANCETransmission OilOil Change1. Remove the fill plug.2. Place a drain pan under the gearcase.3. Remove the drain plug. Allow the oil to drai

85MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Check1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level. 2.

86MAINTENANCEActive Descent Control (ADC) FluidIf your vehicle is equipped with Active Descent Control, there are two fluid levels that must be mainta

6SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on th

87MAINTENANCEActive Descent Control (ADC) FluidFluid Change1. Position the vehicle on a level surface. Before performing the fluid change, allow the v

88MAINTENANCECooling SystemThe engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recov

89MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain t

90MAINTENANCEBrakesHand BrakeThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The

91MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

92MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are fo

93MAINTENANCETiresRefer to the specifications section beginning on page 128 for recom-mended tire type, size and pressure.Tire Tread DepthAlways repla

94MAINTENANCETiresWheel Installation1. Place the transmission in PARK.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem towa

95MAINTENANCEAir Filter1. Remove the seat.2. Release the air box cover clips, and remove the air box cover.3. Loosen the clamp and remove the filter.4

96MAINTENANCELightsWhen servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot