WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. 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 if it has been removed, please call 1-800-342-3764 for assistance.
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Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
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TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 37 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 68 MAINTENANCE AND LUBRICATION . . . . . . . . . 69 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys.
SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
Operator Safety SAFETY S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 62. Always check the terrain carefully before you descending a hill. Shift your weight backward. Never travel down a hill at high speed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 63. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the single lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, then lock the parking brake. If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified in the owner’s manual and on safety decals.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoS S S S S S line. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: WARNING 7077920 34
Safety Decals and Locations WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7078253 SAFETY ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual. 7079780 Chain Freeplay Is Important. Adjust Freeplay to 3/16″ - 3/8″ DO NOT Overtension. See Owner’s Manual.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
FEATURES AND CONTROLS Electrical Switches 3 1 2 WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) OFF RUN OFF This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch.
FEATURES AND CONTROLS WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Light Switches The light switch is located on the left handlebar (1).
FEATURES AND CONTROLS WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine.
FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. 1 The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.
Brakes FEATURES AND CONTROLS Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. 1 2 WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the brake lever two or three times, then squeeze and hold. 2. Push the park brake lock (1) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever.
Auxiliary Brake FEATURES AND CONTROLS WARNING Aggressively applying the auxiliary rear brake when backing downhill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 51 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, below the fender. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 7 to 10 mile (11.2 to 16 km) range on reserve gas.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward N: Neutral R: Reverse 1 F N R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.
FEATURES AND CONTROLS Recoil Starter If the battery has been drained or 2 1 damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.
FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris exclusive, AWD system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in AWD and the AWD 1 indicator light (2) will be on. 2 When in AWD, the front hubs will automatically engage any time the rear wheels lose traction.
FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted. Disengage the hubs by stopping, shifting to reverse, and backing for a short distance.
OPERATION Break-In Period The break-in period for your new 4-cycle Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your ATV is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures. 2. Fuel and oil tanks - Fill both tanks to their proper levels. 3.
OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on. 2.
OPERATION Starting the Engine Starting a Cold Engine 3. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 4. Turn 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 engine starts. If the engine does not start, release the key and wait five seconds. Then activate the starter for another five seconds. Repeat this procedure until the engine starts. 5.
Starting the Engine OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank valve to ON, sit on the vehicle, and turn the engine stop switch to RUN. 3.
OPERATION Hauling Cargo 2/3 1/3 WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow the procedures and precautions outlined in this owner’s manual and on safety decals when hauling cargo. Accessory racks and hitches are available from your Polaris dealer.
Hauling Cargo OPERATION Procedures and Precautions S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle overturn. S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE.
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly.
OPERATION Driving Safely Making Turns Your Polaris ATV 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 slightly. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4.
OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2.
OPERATION Driving Safely Driving Uphill 25_ Maximum WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
Driving Safely OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. If all forward speed is lost: Keep your weight uphill. Apply the single lever brake, gradually.
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single brake lever. NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. WARNING Excessive speed can cause loss of control and lead to serious injury or death.
OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn: 1.
OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 1 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle.
Driving Safely OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration. 4. Shut off the fuel supply.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information. Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; apply Polaris dielectric grease to socket when replaced " Air filter, Weekly Weekly Inspect; replace as needed " Transmission oil 20 hrs. Monthly Inspect level monthly; change annually 20 hrs. Monthly Check terminals; clean 20 hrs. Monthly Inspect; replace annually and as needed J Brake pad wear 10 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Miles Frequency Remarks Carburetor float bowl 50 hrs. 6 months Drain bowl periodically and prior to storage J Throttle Cable/ETC 50 hrs. 6 months Inspect; adjust; lubricate; replace if necessary L Choke (enricher) 50 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Frequency Remarks 100 hrs. 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years 100 hrs. 12 months Replace annually Radiator 100 hrs. 12 months Inspect; clean external surface Cooling system hoses 100 hrs. 12 months Inspect " Front hubs (AWD) 100 hrs. 12 months Change fluid annually J Clutches (drive and 100 hrs.
MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, such as wet or dusty conditions L Polaris Premium All Season Grease or grease conforming to NLG F ∆ No.
MAINTENANCE AND LUBRICATION Lubrication Recommendations (2) (3) (1) (4) (5) (7) (6) (10) (8) (9) 4 or 8 o’clock position- (end view) 75
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 117 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check 1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds, then stop the engine. 3. Remove the dipstick (1), which is located on the left side of the vehicle. 1 4. Wipe the dipstick dry with a clean cloth. Reinstall it and screw it completely in. NOTE: The dipstick must be screwed completely in to keep the angle and depth of the stick consistent. 5. Remove the dipstick and read the oil level.
MAINTENANCE AND LUBRICATION Lubrication Recommendations CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin. Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 9. Place shop towels beneath the oil filter (1). Using an oil filter wrench, turn the filter 2 counterclockwise to remove. 10. Using a clean, dry cloth, clean the filter sealing surface on the crankcase. 1 11. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine. 12.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Maintain the oil level at the bottom of the fill hole threads. Change transmission oil annually. We recommend the use of AGL Synthetic Gearcase Lubricant. See page 117 for the part numbers of Polaris products. 1.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Maintain the oil level at the bottom of the fill plug threads. Change the oil annually. We recommend the use of Polaris Angle Drive Fluid. See page 117 for the part numbers of Polaris products. 1. Position the ATV on a level surface. 2. Remove the fill plug (1) and check the oil level. 3.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Also check for correct slack adjustment. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).
MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out. 1. Set the handlebars in a straight-ahead position.
MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation, such as in hilly country or in muddy terrain. WARNING Never store or use a partial bottle of brake fluid.
MAINTENANCE AND LUBRICATION Adjustments Brakes 1. Check the brake system for fluid leaks. 2. Check the brakes for excessive travel or spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″ (.1 cm), or about the thickness of a U.S. dime. 3/64″ (.1 cm) Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system.
MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.
MAINTENANCE AND LUBRICATION Adjustments WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars 1 The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover to access the handlebar bolts (1). 2.
MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly.
MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Make sure the transmission is in gear with the parking brake locked. 2. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel nuts and finger tighten. 4. Lower the vehicle to the ground. 5. Torque the wheel nuts according to the wheel nut torque specifications chart.
MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. 1/8I (.3 cm) WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death.
MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications. Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions.
MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines 1 without the hitch and 45 ft. lbs. (61 Nm) for machines with a hitch. 8. Tighten the caliper mount bolt to 10-12 ft. lbs. (14-17 Nm) 9. Remove the pin punch. 10.
MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool). 1 The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary. 1.
MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin.
Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and replace it with a new lamp. 3. Test the taillight/brakelight to 1 see that it’s working. 4. Reinstall the gasket and lens cover. Indicator Lamp Replacement 1.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 1. Remove the seat, release the clips, and remove the 2 air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 5. Reinstall the filter into the air box and tighten the clamp.
MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 114. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the airbox for any water. Drain and dry it if water is present. 3. Turn the fuel valve off. 4.
MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, 1 always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.
MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt “pinch.
MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection. Do not stand behind or in front of the vehicle while purging.
Battery MAINTENANCE AND LUBRICATION WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. Disconnect the black (negative) battery cable first. 3.
MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging. Power plug leads may need to be bent down so that the battery cover can be installed. Battery Charging The following battery charging instructions apply only to the installation of a YUASA activated, sealed battery.
Battery MAINTENANCE AND LUBRICATION Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12.8 volts May need slight charge, if no charge given, check in 3 months 3-6 hours 50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 117 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 117 for the part numbers of Polaris products. Fluid Levels Inspect the following fluid levels and change if necessary: front gearcase; transmission; front hubs; brake fluid (change every two years or as required if fluid looks dark or contaminated). Engine 1. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove the spark plug. 3.
MAINTENANCE AND LUBRICATION Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly. 4. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope. See illustration. 5. Always place the transmission in gear and lock the parking brake.
SPECIFICATIONS 2004 Scrambler 500 4x4 Body Style Gross Vehicle Weight Fuel Transmission Oil Coolant Engine Oil Front Rack (Accessory) Rear Rack (Accessory) Hitch Towing Rating Hitch Tongue Weight Capacity Unbraked Trailer Towing Capacity* Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Pilot Air Jet Pilot Sc
2004 Scrambler 500 4x4 Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Front Drive (ratio) Final Drive (ratio) Drive Chain Front Tires Rear Tires SPECIFICATIONS Drive System PVT Side Lever (F-N-R) 4.74/1 3.06/1 2/1 13/36 76P 520 O-Ring 23 x 7-10 (4 psi) 22 x 11-10 (3 psi) Suspension and Brakes Front Suspension: Mac Strut 8.2 in. (20.8 cm) travel Rear Suspension: Progressive Rate 10.5 in. (26.
SPECIFICATIONS 2004 Scrambler 500 4x4 Jetting Chart Altitude AMBIENT TEMPERATURE Below 40° F (Below 5° C) +40°F and above (+5°C and above) Meters (Feet) 0-1800 (0-6000) 160 155 1800-3700 (6000-12000) 152.5 147.
POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2871567 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (16 gal.) Gearcase / Transmission Lubricants 2873602 AGL Synthetic Gearcase Lubricant (qt.) 2873603 AGL Synthetic Gearcase Lubricant (gal.) 2873604 AGL Synthetic Gearcase Lubricant (2.5 gal.) 2871653 Angle Drive Fluid (8 oz.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline.
Engine Doesn’t Turn Over TROUBLESHOOTING Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition con
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
INDEX A E Accessories . . . . . . . . . . . . . . . . . . . 69 Adjustments . . . . . . . . . . . . . . . . 85-95 Age Restrictions . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . 100 All Wheel Drive . . . . . . . . . . . . . 47-48 Auxiliary Brake . . . . . . . . . . . . 43, 87 AWD . . . . . . . . . . . . . . . . . . . . . . 47-48 Engine Storage . . . . . . . . . . . . . . . 112 Equipment Modifications . . . . . . . . 11 Exhaust Emission Control System . 68 B Battery .
INDEX O S Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Oil Change . . . . . . . . . . . . . . . . . 80-81 Oil Filter Change . . . . . . . . . . . . 80-81 OPERATION . . . . . . . . . . . . . . . 49-67 Operator Safety . . . . . . . . . . . . . . . 7-31 Override Switch . . . . . . . . . . . . . . . 37 Starting a Warm Engine . . . . . . . . . 53 Starting the Engine . . . . . . . . . . . 51-53 Steering Assembly . . . . . . . . . . . . . 88 Stop Switch . . . . . . . . . . . . . . . . . . .
