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.
Copyright 2004 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.
WELCOME We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual.
TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. 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. If both keys are lost, the ignition switch must be replaced.
VEHICLE IDENTIFICATION NUMBERS Vehicle Model Number: Frame VIN (1)(left side): Engine Serial Number (2)(right side): Key Number (3): 7
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 C replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations WARNING WARNING WARNING DNever operate this vehicle on HILLS steeper than 25 degrees 25°. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. DREVERSE operation can be dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns. Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
SAFETY Safety Decals and Locations WARNING G 7172566 Location E F H I E D 10 Location F
SAFETY Safety Decals and Locations ATTENTION S S Location G S Operation of this vehicle without the air filter element will severely damage the engine. Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details.
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.
Safe Riding Gear SAFETY 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. 4. Boots The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots. 5.
SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious 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.
Operator Safety SAFETY Know Your Vehicle As the operator of the ATV, you are responsible for your safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your ATV, including safe operating procedures. Safety Training When you purchased your new Polaris ATV, your dealer offered a hands-on safety training course covering all aspects of vehicle safety.
SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. 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 vehicle 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.
Operator Safety SAFETY CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. NOTE: A note will alert you to important information or instructions.
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.
Operator Safety SAFETY S Never operate an ATV on a public street, road or highway, including a dirt or gravel road. S Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds.
SAFETY Operator Safety S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. 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.
Operator Safety SAFETY S Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible. S Always use proper procedures if you stall or roll backwards while climbing a hill.
SAFETY Operator Safety S Avoid operating the ATV through deep or fast-flowing water. If it’s unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.
Operator Safety SAFETY Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
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.
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD: Only operators with advanced skills and substantial experience should operate this ATV.
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a child under the minimum age recommendation operates this ATV. Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.
Operator Safety 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 adversely affect the handling 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.
Operator Safety 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.
Operator Safety 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.
Operator Safety 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: Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN: Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footpeg, it could come into contact with the rear wheels and lead to accident or injury.
Operator Safety 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.
Operator Safety 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.
Operator Safety 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 79. Always check the terrain carefully before 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 80. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Stalling, rolling 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 front brakes gradually. When fully stopped, apply 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.
Operator Safety 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 in the owner’s manual. Always maintain proper tire pressure as described in the owner’s manual and on safety decals.
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Operating the ATV with improper modifications. WHAT CAN HAPPEN: Improper installation of accessories or modification of the ATV may cause changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD: Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc.
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating on frozen bodies of water. WHAT CAN HAPPEN: Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD: Never operate the ATV on a frozen body of water. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury.
Operator Safety SAFETY WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine 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.
FEATURES AND CONTROLS Engine Electrical Switches 3 2 48 1
Engine Electrical Switches FEATURES AND CONTROLS 1. Start Button - The start button engages the starter. Always release the start button as soon as the engine starts. 2. Engine Stop Switch - The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of an emergency. The engine will not start or run when the switch is in the OFF position. 3. Main Key Switch - To start the engine, the main key switch must be in the RUN position.
FEATURES AND CONTROLS Lights 1 1. 2. 3. 4.
Light Switches FEATURES AND CONTROLS The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the engine stop switch is in the RUN position. 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.
FEATURES AND CONTROLS WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service 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.
Electronic Throttle Control FEATURES AND CONTROLS This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease. WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety.
FEATURES AND CONTROLS Foot Brake Your Polaris ATV has a foot pedal (1) that activates the rear brakes. It’s located in front of the right-hand footpeg (2) and is operated by the right foot. If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding. Check the brake fluid level frequently for the foot brake system. The reservoir is located behind the right side panel. Maintain the fluid level between the MIN and MAX marks.
Brake Lever FEATURES AND CONTROLS 1 The Predator ATV has a single brake lever for the front 2 3 brakes. It’s located on the right handlebar. The front brakes are applied by squeezing the brake lever (1) toward the handlebar. The front brakes are hydraulically activated disc type brakes. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm.
FEATURES AND CONTROLS Master Cylinder The master cylinder (2) is located on the right-hand handlebar. Check the brake fluid level before each ride. The fluid level can be seen through the indicator window (3) 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. NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only.
Parking Brake FEATURES AND CONTROLS 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. Place the transmission in first gear or neutral. 2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 3. Push the park brake lock (2) forward to engage the lock. Release the brake lever. 4.
FEATURES AND CONTROLS Parking Brake Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. S Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located under the fuel tank on the left side of the ATV. 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 5 to 8 mile (8 to 13 km) range on reserve gas. Always refill the gas tank as soon as possible after using the main supply. 1 Always return the valve to the ON position after refueling.
FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged. Choke The choke assists in starting a cold engine.
Manual Shift FEATURES AND CONTROLS Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released. To upshift to a higher gear, place the toe of your boot under the gear shift pedal and raise the pedal one full stroke. To downshift, place your foot on the gear shift pedal and depress the pedal one full stroke. See page 62.
FEATURES AND CONTROLS Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral. 2. Squeeze and hold the brake lever. NOTE: 3. 4. 5. 6. 7. Do not squeeze the throttle lever. Squeeze the clutch lever to disengage the clutch. Depress the gear shift pedal one full stroke to shift into first gear. Release the brake lever.
Manual Shift Reverse Lock-Out Switch The reverse lock-out switch (1) prevents the operator from shifting into reverse unintentionally. 1. Place the transmission in first gear. See page 61. 2. Rotate the lock-out switch forward to unlock the transmission. 3. Shift into reverse gear. NOTE: FEATURES AND CONTROLS 1 The lock will automatically re-engage when the transmission is shifted out of reverse gear.
FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear.
Fuel Safety OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck.
OPERATION Break-In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris Predator is defined as the first one hour of operation, or the time it takes to use the first full tank of gasoline. Follow the break-in period with an additional two hours of cautious operation. No single action on your part is as important as following the procedures for a proper break-in.
Break-In Period OPERATION 1. Fill the fuel tank with gasoline. See page 60. 2. Check the oil level on the dipstick. See page 103. Add oil if necessary to maintain the level between the safe and add marks. 3. Allow the engine sufficient time to warm up before operating. 4. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 5. Vary the throttle positions. Do not operate at sustained idle. 6.
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. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Brake fluid Foot brake Clutch lever Suspension, front and rear Steering Ensure proper operation Ensure proper level Ensure proper operation Check for proper operation and correct adjustment.
OPERATION Pre-Ride Inspection Pre-Ride Checklist Frame nuts, bolts, fasteners Fuel and oil Coolant level (if applicable) Coolant hoses (if applicable) Throttle Indicator lights / switches Engine stop switch Air filter, pre-filter Headlamp Brake light / tail lamp Riding gear A-arm ball joints Inspect, ensure tightness Ensure proper levels Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Check operation, apply Polaris dielectric grease to
OPERATION Starting a Cold Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. 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. 1.
OPERATION Starting a Cold Engine 2. Sit on the ATV and pull the choke knob (1) out until it stops. NOTE: NOTE: If the knob doesn’t stay where positioned, increase the tension by rotating the tension adjusting nut clockwise. The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting.
OPERATION Starting a Cold Engine NOTE: If starting the engine while in neutral, the neutral indicator light should be on. If it isn’t, disengage the clutch and shift the foot pedal to find neutral. See page 61. If starting the engine while in gear, apply the hand brake and squeeze the clutch lever fully to disengage the clutch. 5. Press the start button to start the engine. Activate the starter for a maximum of five seconds. Release the start button immediately when the engine starts.
Starting a Warm Engine OPERATION Follow the procedure for starting a cold engine, but do not use the choke. If the engine has cooled to a point where it does not readily start, intermittent use of the choke (pulled half way out) may be necessary. If you believe the engine is over-choked when warm, push the choke lever completely in and depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts.
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. See page 62. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb while slowly releasing the clutch lever to begin driving. 6. Drive slowly.
Driving Safely OPERATION Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turning, and the inside tire slips traction slightly. To 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 footpeg.
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.
OPERATION Driving Safely 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 footpegs and transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Be alert and prepared to take emergency action. This may include quick dismounting of the vehicle. 25_ Maximum WARNING Braking and handling are greatly affected when operating in hilly terrain.
OPERATION Driving Safely Driving Across Hills 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. If you enter into a situation where sidehilling is unavoidable: 1. Slow down. 2. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footpegs. 3.
Driving Safely OPERATION 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. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid in slowing. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
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.
Driving Safely OPERATION Turning Around on a Hill 5. Staying uphill of the ATV, turn the handlebars full left. Reach across the handlebar and apply the front brakes to unlock the park brake. 6. With the front brakes applied, pull in the clutch 8’ lever. Use the brakes to slowly allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward. Uphill 7. With the front brakes still applied, release the clutch lever and lock the park brake.
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. See illustration. 5. Shut off the fuel supply.
Driving Safely OPERATION 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 Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and 1 obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
Driving Safely OPERATION Driving Through Water CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footpeg level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Back slowly. 3. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly while backing.
Driving Safely OPERATION Driving in Reverse 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. Do not use the override switch unless additional power is required for vehicle movement. Use extra caution. Drive slowly. Avoid backing on inclines. Avoid turning at sharp angles. NOTE: This Polaris ATV is equipped with a reverse speed limiter.
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.
EMISSION CONTROL SYSTEMS Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the following pages. A tool kit is provided in the storage compartment under the seat. Tool Kit S S S S S S S Spark plug socket and handle Open end wrench, 1/2 in.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
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. Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item " E " " MAINTENANCE AND LUBRICATION Remarks Hours Calendar Miles (Km) Brake systems/fluid -- Pre-Ride -- Inspect; maintain fluid level between fill lines Tires -- Pre-Ride -- Inspect Wheels/lug nuts -- Pre-Ride -- Inspect; tighten Frame fasteners -- Pre-Ride -- Inspect; tighten Air filter and Pre-cleaner -- Pre-Ride -- Inspect; clean Coolant -- Pre-Ride -- Inspect level; add as needed Fuel
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (Km) Engine stop switch -- Pre-Ride -- Check operation " Steering -- Pre-Ride -- Check for free operation and loose components " Air box sediment tubes -- Pre-Ride -- Drain deposits when visible Headlamp -- Pre-Ride -- Check daily; apply Polaris dielectric grease to connector when replaced Tail lamp/brake lamp -- Pre-Ride -- Check daily A-arm
Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Calendar Miles (Km) -- Weekly -- Brake pad wear 10 H Monthly 100 (160) Inspect periodically Oil Change 10 H 6M 100 (160) Perform break-in service after first hour of operation Oil Filter 10 H 6M 100 (160) Replace with oil change E Air filter, main element J " " E Remarks Hours " E MAINTENANCE AND LUBRICATION Inspect; replace as needed Battery 20 H Monthly 200 (320) Check terminals; clean " Engi
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (Km) Carburetor float bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage Throttle Cable/ETC Switch 50 H 6M 500 (800) Inspect; adjust; replace if necessary Choke (enricher) cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary " Drive chain(s) 50 H 6M 500 (800) Inspect daily; adjust and lubricate if needed " Engi
Periodic Maintenance Chart MAINTENANCE AND LUBRICATION Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (Km) " F A-Arm (A) 50 H 3M 500 (800) Inspect; tighten fasteners; grease (also after washing ATV or driving in water) " F Rear axle/ Rear eccentric (B) 25 H 3M 250 (400) Inspect; grease (also after washing ATV or driving in water) " F Upper steering post (C) 50 H 6M 500 (800) Inspect; tighten fasteners; grease after washing ATV or driving in water A
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (Km) Coolant strength 50 H 6M 500 (800) Coolant system pressure test 100 H 12 M 1000 (1600) Pressure test system annually E Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed J Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, pump and carburetor; replace lines every two years J Ignition Timing -- 12 M
Periodic Maintenance Chart MAINTENANCE AND LUBRICATION Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (Km) Radiator 100 H 12 M 1000 (1600) Inspect; clean external surface; change coolant every 2 years Cooling system hoses 100 H 12 M 1000 (1600) Inspect Engine mounts 100 H 12 M 1000 (1600) Inspect Brake fluid 200 H 24 M 2000 (3200) Change every two years Spark arrestor 300 H 36 M 3000 (4800) Clean out J Front wheel bearings 300 H 36 M 3000
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.
Periodic Maintenance Record Maintenance Interval Performed Servicing Date MAINTENANCE AND LUBRICATION Servicing Dealer or Person Remarks 101
MAINTENANCE AND LUBRICATION Lubrication Recommendations Performance Synthetic 4-Stroke (PS-4) Oil Polaris highly recommends the use of Polaris PS-4 or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. PS-4 has been specifically formulated for use in high performance engines. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection and prolonged clutch life.
Engine Oil Level MAINTENANCE AND LUBRICATION Check the oil level before each use of the vehicle. The dipstick (1) is located on the left side of the ATV. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for one minute. 3. Stop the engine and remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick completely. NOTE: The dipstick must be screwed completely in to keep the angle and depth of the stick consistent. 5.
MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.
MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filter within a few hours of draining the oil. Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 90. Always change the oil filter whenever changing oil.
MAINTENANCE AND LUBRICATION Oil and Filter Change 1. Place the vehicle on a level surface. 2. Clean the area around the oil tank (1) and crankcase (2) drain plugs with clean shop towels. 3. Run the engine for two to three minutes until warm, then stop the engine. 4. Place a drain pan beneath the oil tank and remove the drain plug. 2 1 CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. 5. Allow the oil to drain completely. 6.
Oil and Filter Change MAINTENANCE AND LUBRICATION 7. 8. 9. 10. 11. Place a drain pan beneath the crankcase and remove the drain plug. Allow the oil to drain completely. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm). Place shop towels beneath the oil filter. Remove the three cover bolts and remove the cover. 12. Pull out the oil filter. NOTE: A spring located behind the filter may pop out as the filter is removed. The spring must be reinstalled with the new filter. 13.
MAINTENANCE AND LUBRICATION Oil and Filter Change 16. Reinstall the spring and install the new filter with the open end facing outward. 17. Install the cover and torque the bolts to 72-78 in. lbs. (8-9 Nm). NOTE: The long bolt must be placed in the forward hole. Step 14 Step 16 18. Remove the dipstick and fill the oil tank with the recommended oil. 19. Place the transmission in neutral and set the parking brake.
Oil and Filter Change MAINTENANCE AND LUBRICATION 20. Prime the oil pump using the procedure on page 110. Then stop the engine and inspect for leaks. 21. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 22. Dispose of the used filter, oil and shop towels properly.
MAINTENANCE AND LUBRICATION Oil Pump Priming This priming procedure must be 1 performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent 2I line (1) approximately 2I (5 cm) from the oil tank. 2. Run the engine for 5-10 seconds at idle. Stop the engine and remove the vent line clamp. If the line is bled properly, you should hear a rush of air, indicating that the line is properly primed and ready for operation.
Air Filter Systems MAINTENANCE AND LUBRICATION 4 1. Unlatch and remove the seat. 2. Loosen the intake duct clamp (1) on the carburetor. 3. Pull the duct (2) off the carburetor. 4. Release the eight airbox cover clips (3) and remove the cover (4). 5. Remove the air filter (5). Inspect and replace if necessary. 6. Remove the pre-filter (6) and breather filter (7). Wash both in soapy water, then rinse, let dry and reinstall.
MAINTENANCE AND LUBRICATION Air Filter Systems 7. 8. 9. 10. Reinstall the air filter. Reinstall the airbox cover and secure the clips. Reinstall the intake duct to the carburetor and secure the clamp. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. CAUTION Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.
Engine Cooling System MAINTENANCE AND LUBRICATION 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. To ensure that the coolant maintains its ability to protect the engine, we recommend that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water.
MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine under the front fender. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool). As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the recovery bottle.
Engine Cooling System MAINTENANCE AND LUBRICATION 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 cap. Radiator Coolant Level 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, inspect the level in the radiator and add coolant if necessary. 1. Remove the pressure cap. 2.
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 Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise (1) to remove the bulb. On the right headlamp, turn the bulb housing clockwise (2) to remove the bulb. 3. Apply dielectric grease to the socket and install the new bulb. Rotate firmly. NOTE: The bulb must be positioned so the harness installs into the lamp at outer side. 4.
MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2 2. Remove the front cab (see page 122). Position the cab upside down on a soft protective surface to prevent scratching. 3. Remove the small adjuster bracket (1) and install it on the new lamp. 4. Remove the large pivot bracket (2) and remove the headlamp.
Lights MAINTENANCE AND LUBRICATION Headlight Assembly Replacement 5. Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab. 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. 7. Adjust for approximately 1/16” clearance between the bracket and the edge of the headlight. Tighten the mounting screws. IMPORTANT: Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freely. 8.
MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2” (5.1 cm) below the mark placed on the wall.
Side Panel Removal MAINTENANCE AND LUBRICATION 1. Unlatch and remove the seat. 2. Remove the four screws (1) securing the side panel. 3. Remove the side panel. 3 5 4 Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the four bolts (2) on the rear fenders of the cab and the two bolts (3), washers and grommets (4) on the top of the cab. 3. Remove the two screws (5) from the rear cab supports. 4. Remove the cab.
MAINTENANCE AND LUBRICATION Front Cab Removal 1. Remove the screws and washers (1) from the front left-hand and right-hand cab mounts. 2. Remove the wire harness connector from the headlights. 3. Loosen the screw (2) located inside the cab under the front cover. 4. Gently pull the cab forward to remove the cab and disengage it from the stand-offs on the fuel tank. 5. Reverse all steps to reinstall the front cab.
Spark Plugs MAINTENANCE AND LUBRICATION S Use NGK DCPR8E spark plugs. S Proper electrode gap is .035″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). CAUTION Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation.
MAINTENANCE AND LUBRICATION Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. 2. Wet Fouled The wet fouled insulator tip is black.
Spark Plugs MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement 1. Remove the side panels and front cab (see pages 121-122). 2. Turn the fuel valve to OFF. WARNING A hot ember on the ATV could cause fuel to ignite. Allow all components to cool sufficiently before accessing the spark plug. Always exercise extreme caution when handling fuel systems and gasoline. Always heed the fuel warnings on page 65.
MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting on the gas tank. 4. Remove the vent hose (2) from the instrument panel, taking note of the hose 2 routing for reinstallation. 5. Remove the tank mounting bolt (3) at the rear of the gas tank. 6. Move the tank rearward and upward over the engine.
Spark Plugs MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement 7. Using the forked end of the spark plug wrench handle, remove the spark plug boot. IMPORTANT: Do not pull on the wire to remove the boot. Doing so may cause a wire disconnection inside the boot. 8. Using the spark plug wrench and handle, rotate counterclockwise to remove the spark plug. 9. Reverse all steps to install the spark plug and reassemble the body. Torque the spark plug to 14 ft. lbs. (19 Nm).
MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Wear eye protection and gloves. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Failure to heed these warnings could result in serious injury or death.
Spark Arrestor Clean-Out MAINTENANCE AND LUBRICATION Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 3. Inspect the screen for wear and damage. Replace if necessary. 4. Remove and inspect the gasket.
MAINTENANCE AND LUBRICATION Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it’s critical to dry it promptly and properly before starting the engine. CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended depth. Serious engine damage WILL occur. Tow or trailer the ATV to your dealer for service.
Vehicle Immersion MAINTENANCE AND LUBRICATION WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts. Stand clear of the spark plug while performing the following steps. 5. Intermittently and briefly touch the starter button in half-second intervals to SLOWLY rotate the engine three or four times. Water will eject from the spark plug hole. 6.
MAINTENANCE AND LUBRICATION Battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.
Battery Installation MAINTENANCE AND LUBRICATION 1. Set the battery in the battery holder. 2. Connect and tighten the red (positive) cable first, then connect and tighten the black (negative) cable. 3. Attach the hold-down strap and reinstall the rear cab. 4. Verify that cables are properly routed. NOTE: When installing a new battery, make sure it’s fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life.
MAINTENANCE AND LUBRICATION Battery Charging (Sealed Battery) The most important part of maintaining a sealed battery is keeping it fully charged. The battery included with your ATV is sealed and the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is less than 12.8 volts, recharge the battery.
MAINTENANCE AND LUBRICATION Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after 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 Tires 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 ATV decal and in the owner’s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (.
Tire Tread Depth MAINTENANCE AND LUBRICATION Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. 1/8I (.3 cm) Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and remove the wheel.
MAINTENANCE AND LUBRICATION Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in gear and lock the parking brake. 2.
MAINTENANCE AND LUBRICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. Bolt Size Specification Front 3/8″ 27 ft. lbs. (36.5 Nm) Rear 3/8″ 27 ft. lbs. (36.
ADJUSTMENTS Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Do not overfill. See page 56. The front brakes are hydraulic disc brakes. They’re activated by squeezing the brake lever toward the handlebar.
ADJUSTMENTS Brakes 1. Always maintain the brake fluid at an adequate level (see page 56). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. 6. Inspect the rear brake disc spline and pad wear surface for excessive wear. NOTE: Pads should be changed when worn to 3/64″ (.1 cm). 3/64″ (.
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 Predator is designed for a neutral toe setting. 1. Set the handlebars in a straight-ahead position. Use tie straps to secure the handlebars to the rear grab bar so they can’t move.
ADJUSTMENTS Toe Alignment 3. Tie an elastic string (2) around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle. 4. Measure the distance from the string to the rim at the front and rear of the front rim (3). The difference between these two measurements should be between 0″ and 1/16″ toe out. NOTE: 2 If you discover improper alignment, see your Polaris dealer for service.
ADJUSTMENTS Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in the illustration so that the axle, swing arm pivot and drive sprocket are aligned horizontally (B).
Chain Tension ADJUSTMENTS Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. NOTE: The chain has a press-on master link. A chain tool must be used if it’s necessary to remove the chain for service. 1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (A). Fasten the strap around the axle and rear bumper tube. 2.
ADJUSTMENTS Chain Tension 1. 2. 3. 4. Loosen the two eccentric locking bolts. Insert a pin punch into the eccentric axle housing. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm).
Steering Assembly ADJUSTMENTS 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.
ADJUSTMENTS Suspension Settings Use a flat blade screwdriver (in tool kit) to make damping adjustments. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.
Front Suspension ADJUSTMENTS Compression Damping (Troy Lee) To adjust the front suspension compression damping, use the adjustment procedures outlined for the rear suspension compression damping on page 153. Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death.
ADJUSTMENTS Front Suspension Spring Preload 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Loosen the jam nut (1). 3. Turn the adjusting ring (2) to the left to increase preload (A). Turn the ring to the right to decrease preload (B). 4. Tighten the jam nut against the adjusting ring. NOTE: 150 See Suspension Settings on page 148.
Rear Suspension The rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend. 2. Loosen the jam nut (1) and back it away from the adjusting ring. 3. Turn the adjusting ring (2) to the left (A) to increase preload. Turn the ring to the right (B) to decrease preload.
ADJUSTMENTS Rear Suspension Rebound Damping 1. Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount. 2. Use a screwdriver make the adjustment. Turn the clicker counter-clockwise to decrease the rebound damping (A). Turn the clicker clockwise to increase rebound damping (B). NOTE: 152 The rebound damping is factory set at 16 clicks from fully closed. See Suspension Settings on page 148.
Rear Suspension Compression Damping The compression damping clicker (1) is located on top of the shock reservoir, under the left rear fender. Use a screwdriver to make adjustments. To increase compression damping, turn the clicker clockwise (A). To decrease compression damping, turn the clicker counter-clockwise (B). The factory setting is at 10 clicks from fully closed. See Suspension Settings on page 148.
ADJUSTMENTS Clutch Lever Freeplay 1. Measure clutch lever freeplay between C the perch and the lever (A). This distance should be 1/8″ - 3/16″ (3.1 mm - 4.7 mm). 2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch B A adjustment screw (B) and lock ring (C). 3. Loosen the lock ring and turn the screw in (clockwise) to increase lever travel. Turn the screw out (counterclockwise) to decrease lever travel. Tighten the lock ring. 4.
ADJUSTMENTS Throttle Cable Freeplay WARNING Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it’s done correctly. Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly. Throttle cable freeplay is adjusted at the handlebar. 1.
ADJUSTMENTS Handlebars If desired, the handlebars can be adjusted for rider preference. WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars, which could result in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate the handlebar bolts (1). 2.
Carburetor/Idle RPM ADJUSTMENTS If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for five minutes, or until operating temperature is reached. 2. Apply the park brake and place the transmission in neutral. 3. Adjust the carburetor idle screw (1) either in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM.
ADJUSTMENTS Carburetor/Idle RPM Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
CLEANING AND STORAGE See page 173 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. Washing the ATV CAUTION Do not use a high pressure washer for washing the ATV. Serious damage will result to wheel bearings, chains, transmission seals, body panels, brakes and decals. Clean your ATV with a garden hose and a pail of mild soap and water.
CLEANING AND STORAGE Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. CAUTION Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surfaces.
CLEANING AND STORAGE See page 173 for the part numbers of Polaris products. Storage Recommendations 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. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly as outlined on page 159.
CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter. See page 105. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube. Breather Filter Inspect and clean or replace the breather filter (inside the airbox). Fluid Levels Inspect all fluid levels and change as outlined in the Maintenance Schedule beginning on page 90.
CLEANING AND STORAGE See page 173 for the part numbers of Polaris products. Storage Recommendations Fog the Engine 1. Start the engine and allow it to warm up. Turn engine off. 2. Unlatch and remove the seat. 3. Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor. 4. Start the engine and spray Polaris fogging oil or a comparable product into the carburetor, following the instructions on the fogging oil container. 5.
CLEANING AND STORAGE Storage Recommendations Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Engine Anti-Freeze Test engine coolant strength and add or change coolant if necessary. Replace coolant every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2” off the ground.
Transporting the ATV CLEANING AND STORAGE 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, as shown in the illustration, using suitable straps or rope. 5. Always place the transmission in first gear and lock the parking brake.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Clogged fuel valve Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old, poor or non-recommended fuel Drain and replace with new fuel Fouled or defective spark plug Inspect plug(s), replace if necessary No spark to spark plug Inspect plug(s), verify stop switch is on Overuse of choke Ins
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Backfires Possible Cause Solution Weak, fouled or defective spark plug Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old, poor or non-recommended fuel Replace with new fuel
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Old, poor or non-recommended fuel Replace with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clean and/or replace spark plugs Fuel is very high octane
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 plug Inspect, clean and/or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connec
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Clogged, dirty or wet air filter Inspect and clean or replace Electronic throttle control (ETC) malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen.
POLARIS PRODUCTS Part # Description Engine Lubricant Part # Description Coolant 2874414 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2871323 60/40 Coolant (gal.) 2874415 PS-4 Oil (gal.) 2871534 60/40 Coolant (qt.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) Additives / Miscellaneous 2871322 Premium All Season Grease (3 oz. cartridge) 2871326 Carbon Clean Plus (12 oz.) 2871423 Premium All Season Grease (14 oz. cartridge) 2870652 Fuel Stabilizer (16 oz.
SPECIFICATIONS Predator 500 Gross Vehicle Weight 645 lbs./292 kg Pilot Jet 45 Fuel Capacity 3.25 gal./12.3 l Main Jet 150 Overall Length 71.5 in./182 cm Needle Jet O-OM Overall Width 47.5 in./121 cm Jet Needle 6CGY07-060-3 Overall Height 45 in./114 cm Alternator Output 200 w @ 3000 RPM Wheelbase 51 in./130 cm Compression Ratio 10.8:1 Ground Clearance 4.5 in./11 cm Starting System Electric Dry Weight 415 lbs./188 kg Carburetor BSR 42mm Minimum Turning Radius 67 in.
SPECIFICATIONS Predator 500 Driving System Type Shift Type Rear Two-Wheel Drive 5-Speed Manual Shift Tire Size/Pressure - Front Tire Size/Pressure - Rear 21 x 7 - 10 / 4 psi 20 x 11 - 9 / 4 psi (Std) 20 x 10 - 9 / 4 psi (Troy Lee) Drive Ratio - Final 14/38 Front Brake Hydraulic Disc Gear Ratio - 1st 2.4 Rear Brake Hydraulic Disc Gear Ratio - 2nd 1.6 (Std) 1.9 (Troy Lee) Parking Brake Hydraulic lock, front wheel Gear Ratio - 3rd 1.3 (Std) 1.
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 COVERAGE AND EXCLUSIONS: WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
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.
HOW TO OBTAIN WARRANTY SERVICE WARRANTY If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
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.
Exported Vehicles WARRANTY How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
Index A C E ADJUSTMENTS . . . . . . . . . . . 140-158 Air Filter Systems . . . . . . . . . . . 111-112 Clutch Lever Freeplay . . . . . . . . . . 154 Compression Damping . . . . . . . . . . 153 Compression Damping (Troy Lee) . 149 Coolant Level, Radiator . . . . . . . . . 115 Coolant Level, Recovery Bottle . . . 114 Cooling System . . . . . . . . . . . . . 113-114 Crankcase Emission Control System . 88 Engine Oil Level . . . . . . . . . . . . 103-104 Equipment Modifications . . . . . . . . .
Index L-M P S Light Switches . . . . . . . . . . . . . . . . . 51 Lights . . . . . . . . . . . . . . . . . 50, 116-120 Lubrication Recommendations . . . . 102 MAINTENANCE AND LUBRICATION . . . 90-139 Maintenance Record . . . . . . . . . 100-101 Making Turns . . . . . . . . . . . . . . . . . . 75 Manual Shift . . . . . . . . . . . . . . . . . 61-64 Master Cylinder . . . . . . . . . . . . . . . . 56 Periodic Maintenance Schedule . . 90-92 POLARIS PRODUCTS . . . . . . . . . 173 Pre-Ride Inspection . . . .
