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.
FOREWORD Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATV’s). Built with American engineering and manufacturing know-how, it is designed to provide superior riding comfort, enjoyment and safety. This manual is furnished to ensure that the operator is aware of safe operating procedures. It also includes information about the general care and maintenance of your ATV. Carefully read the following pages.
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: • Read this manual and all labels carefully and follow the operating procedures described.
• Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed. • Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill.
WARNING indicates a potential hazard which could result in serious injury or death. Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes.
The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its products.
CONTENTS UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SAFETY WARNING AND OPERATION DECALS . . . . . . . . . . . 3-13 DAILY PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-33 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . 34 CONTROL AND PARTS FUNCTIONS . . . . . . . . . . . . . . . . . . . 35-54 STARTING THE ENGINE . . . . . . . . . . . . .
UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 18 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment.
UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! WARNING CAUTION NOTE Indicates a potential hazard which could result in serious injury or death. Indicates a potential hazard which may result in minor personal injury or damage to the ATV.
SAFETY WARNING AND OPERATION DECALS NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
SAFETY WARNING AND OPERATION DECALS 1 4
SAFETY WARNING AND OPERATION DECALS 2 5
SAFETY WARNING AND OPERATION DECALS 2 WARNING READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE. TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS OR DURING TURNS. KEEP FEET ON FOOTRESTS AT ALL TIMES. HILL CLIMBING IS DANGEROUS, and should be attempted only by experienced operators.
SAFETY WARNING AND OPERATION DECALS 6 5 3 4 7 6 7
SAFETY WARNING AND OPERATION DECALS 7 5 ETC This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to your Owner’s Manual for details. 7072724 WARNING OVER-LOADING CAN CAUSE STEERING, TIPPING AND BRAKING PROBLEMS RESULTING IN LOSS OF CONTROL. LOSS OF CONTROL CAN CAUSE SEVERE INJURY OR DEATH. DO NOT OVERLOAD THE ATV. SEE YOUR OWNER’S MANUAL.
SAFETY WARNING AND OPERATION DECALS 7 This decal is found only on models with dual racks. WARNING LOAD DISTRIBUTION WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.
SAFETY WARNING AND OPERATION DECALS 7 This decal is found on models with only rear racks. WARNING RACK LOAD WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.
SAFETY WARNING AND OPERATION DECALS 8 8 ATTENTION DOPERATION OF THIS VEHICLE WITHOUT THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE. DCLEAN AIR FILTER OFTEN, MORE FREQUENT CLEANING REQUIRED IN DUSTY CONDITIONS. (Under Seat) WARNING BRAKE SHIELD COVERS MOVING PARTS. CONTACT WITH MOVING PARTS MAY RESULT IN SEVERE INJURY. DO NOT REMOVE BRAKE SHIELD. (On right side) 11 7075339 DLiutilisation de ce véhicule sous liélément filtre endommage sévèrement le moteur.
SAFETY WARNING AND OPERATION DECALS 10 9 9 DO NOT ATTEMPT ENGINE OR CLUTCH MODIFICATION. DOING SO CAN CAUSE IMBALANCE AND/OR EXCESSIVE ENGINE RPM. EXCESSIVE ENGINE RPM CAN CAUSE PART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH. DO NOT MODIFY ENGINE OR CLUTCH. 7077377 10 WARNING BELT -- CLUTCH GUARD COVERS MOVING PARTS. CONTACT WITH MOVING PARTS MAY RESULT IN SEVERE INJURY OR DEATH. DO NOT OPERATE VEHICLE WITH GUARD REMOVED.
SAFETY WARNING AND OPERATION DECALS ATTENTION Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory setting: 40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). 7073761 Chain Freeplay Is Important. Collapse Suspension To Adjust. DO NOT Overtension. See Owner’s Manual. Torque Eccentric Bolts To 60 Ft. Lbs. Le jeu libre de la chaine est important. Écrasez la suspension pour L’adjuster.
DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts. Item/Inspection Procedure 1. Tires - check condition and pressures 2.
OPERATION WARNINGS 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 Industries Inc.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN The ATV’s tires are designed for off-road use only; not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. See page 63 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 65 through 68. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 67. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. See page 68. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner’s Manual. WARNING POTENTIAL HAZARD Skidding or sliding.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this 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. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. See page 69. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual Supplement for this vehicle. Always maintain proper tire pressure as described in the Owner’s Manual Supplement.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to 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 greater distance for braking.
VEHICLE IDENTIFICATION NUMBERS 2 On recoil housing 1 VIN on the lower left side of the frame tube Important: Record these numbers from your ATV in the spaces provided. 1. Frame VIN 2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Record your ignition key number here. It is a four digit number found stamped on the key. In the event the key is lost, replacement can be made by supplying your dealer with this number.
CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 3 1 4 2 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.
CONTROL AND PARTS FUNCTIONS Light Switches and Indicator Lights Switches Each Polaris ATV has a main switch. It is located on the right hand side of the machine and operated with a key. The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: Will not light unless the main switch is on. Indicator Lights Each Polaris ATV has indicator lights.
CONTROL AND PARTS FUNCTIONS With engine running, verify function of indicator lights each time ATV is used. WARNING This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. NOTE: The taillight is on whenever the main switch (key) is in the on position. Turn the key off to prevent battery drain.
CONTROL AND PARTS FUNCTIONS Engine Throttle and Choke Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle.
CONTROL AND PARTS FUNCTIONS Throttle Control/Brakes Throttle Control Lever Stop The throttle control lever incorporates an adjustable stop. This can be adjusted to limit the amount of throttle opening by loosening the screw (A) and sliding the stop to a desired setting. Then tighten screw. A Front and Rear Brakes The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride.
CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake Maximum 1. Squeeze the left hand brake lever two or three times and hold it. Minimum 2. Rotate the park brake lock into the notches on the master cylinder body. Release the brake lever. 3. To release the parking brake lock, squeeze the brake lever. It will return to its released position. Parking Brake Lock WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV.
CONTROL AND PARTS FUNCTIONS Auxiliary Mechanical Brake Auxiliary Brake Pedal Your Polaris ATV has an auxiliary mechanical brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the hydraulic brake system, especially if the hydraulic system becomes inoperative. WARNING: Use caution when applying the auxiliary mechanical brake.
CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your machine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter. The transmission selector lever has three or four positions: high forward; reverse; neutral; and low forward or forward; reverse; and neutral.
CONTROL AND PARTS FUNCTIONS Demand 4 Drive (Found on models with All Wheel Drive) AWD Indicator Light AWD Button Out “Off” AWD Button AWD Button in “On” Exclusive Demand 4 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch on the right handlebar. When the switch is “off” the 4x4 is in 2 wheel drive at all times.
CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 4 Drive and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again. You can tell if only one front hub is engaged if the handlebars pull to one side.
CONTROL AND PARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle. 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.
CONTROL AND PARTS FUNCTIONS Engine Cooling System Gen II Radiator Coolant Level Inspection NOTE: This procedure is only required 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. WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.
CONTROL AND PARTS FUNCTIONS Engine Cooling System To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System 1 2 The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual Supplement for tank capacity. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane. On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine. Refer to you Owner’s Manual Supplement to determine the type of engine your vehicle has.
CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. WARNING Gasoline is highly flammable and explosive under certain conditions. DAlways exercise extreme caution whenever handling gasoline. DAlways refuel with the engine stopped and outdoors or in a well ventilated area.
CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F to 120° F.
CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Place a drain pan beneath the oil tank and remove the drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. Allow oil to drain completely. Install a new sealing washer (PN 5850135) on oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.
CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil. CAUTION: Engine warranty coverage may become void if other brands are substituted. Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifically designed for today’s 2-cycle engines.
CONTROL AND PARTS FUNCTIONS Recoil Starter Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. Polaris engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting. 1.
CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained. CAUTION: Make sure the manual start handle is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.
STARTING THE ENGINE Procedure for Starting a Cold Engine 1. Place the transmission in neutral and push the vehicle to a level surface. 2. Lock the parking brake. 3. Turn the fuel tank valve to ON. 4. Sit on the vehicle. “FULL” “HALF” “OFF” Choke Lever Side View 5. Move the choke lever to the FULL position. 6. Turn the ignition key to ON and the engine stop switch to RUN. 7. Press the starter button. 8. Do not press the throttle while starting the engine. 9. Press starter button for five seconds.
VEHICLE BREAK-IN PERIOD 2 Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. CAUTION: Use only Polaris injection oil. Never substitute or mix oil brands.
VEHICLE BREAK-IN PERIOD 4 Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a serious head injury.
CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Never exceed the following weights. Model Total Load Capacity (includes driver & cargo) Front Rack Cargo Maximum Rear Rack Cargo Maximum Sportsman 500 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs.
CARGO WEIGHT DISTRIBUTION 2/3 of Load on Rear Rack 1/3 of Load on Front Rack WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.
DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts. Item/Inspection Procedure 1. Tires - check condition and pressures 2.
RIDING 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, 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 and all transmission shifting is done automatically. 6.
RIDING Making Turns Practice making turns at slow speeds. Polaris ATVs are 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 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.
RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 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.
RIDING Traveling Uphill 25_ Maximum Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills. 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Remain alert and be prepared to take emergency action. This may include quick dismounting of the ATV. WARNING Braking and handling are greatly affected whenever operating in hilly terrain. Loss of vehicle control or overturning of the ATV could occur.
RIDING Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle directions.
RIDING Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs. WARNING Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.
RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1. 2. 3. 4. 5. Stop and lock the parking brake while maintaining body weight uphill. Leave transmission in forward and shut off engine. Dismount on left or uphill side of ATV. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).
RIDING Crossing Streams Your Polaris ATV can operate through water up to depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 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. CAUTION: Should your ATV become immersed, it will be necessary to take it to your dealer as soon as possible.
RIDING Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen obstacles. DKeep alert and constantly look for obstacles on the trail. WARNING indicates a potential hazard which could result in serious injury or death.
RIDING Backing Up Backing Up 1. 2. 3. 4. 5. 6. Whenever backing up, always avoid backing downhill. Back slowly. When in reverse, apply the brakes lightly for stopping. Avoid turning at sharp angles in reverse. Never open the throttle suddenly while backing. Never activate override button while throttle is open. Loss of control may result. NOTE: This vehicle is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased.
RIDING Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in gear. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 5. Shut off fuel supply. WARNING indicates a potential hazard which could result in serious injury or death.
BATTERY Battery CAUTION Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. Maintain between upper and lower level marks To refill use only distilled water. Tap water contains minerals which are harmful to a battery.
BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV, being careful not to tip it sideways and spill any electrolyte.
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S.
MAINTENANCE Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the engine. Purge accumulated Clean Out Plugs carbon from the system by momentarily revving the engine several times. 3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.
MAINTENANCE Spark Arrestor (Cont.) WARNING DDo not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. DBecause of the increased fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. DWear eye protection. DDo not stand behind or in front of the vehicle while purging the carbon from the spark arrestor. DNever run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas.
MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat.
MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently.
MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Odometer Frequency Remarks JL Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.
MAINTENANCE Periodic Maintenance Schedule (Cont.
MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil (2-Cycle) Polaris Injection Oil Fill oil tank. See page 48. As needed, when refueling 2.Engine OIl (4-Cycle) Polaris Premium 4 Synthetic 0W40 Add to proper level on dipstick. See page 50. Check level daily. 3. Brake Fluid DOT 3 Only Maintain level between fill lines. See page 39. As required; change every two years or 200 hours 4.
MAINTENANCE Lubrication Recommendations 14. Front A Arm Pivot Shaft Grease**∆ Locate fitting on pivot shaft and grease with grease gun. Every 3 months or 50 hours 15. Counter Balance Housing (400) SAE 10/30 Check level on dipstick and add oil as necessary. Change annually. To change oil see page 117. Check monthly and change annually 16. Output Shaft Support Bearing Grease ** Locate fitting on bearing and grease with a grease gun. Monthly or at 20 hours 17.
MAINTENANCE Lubrication Recommendations 5. Front Gear Case 4. Transmission Full Fill plug Operating Range 7. Front Prop Shaft (U-Joint) 8. Propshaft Yoke 6. Rear Halfshaft (U Joint) 12. Axle Cardan Front Drive (AWD Models) 9. Speedo meter Cable 15.
MAINTENANCE Lubrication Recommendations 4WD 17. Steering Post Bushings 25. Tie Rod End 25. Tie Rod End Lower 11. Demand 4 Hubs Upper 14. Front A-Arm Pivot Shaft 11. 4 O’clock position 13. Ball Joint Trail Boss 25. Tie Rod Ends 17. Steering Post Bushings Lower Upper 14. Front A-Arm Pivot Shaft 85 13.
MAINTENANCE Lubrication Recommendations 25. Tie Rod End 11. Demand 4 Hubs 14. Front A-Arm Pivot Shaft 11. 4 O’clock position 13. Ball Joint 17. Steering Post Bushings Lower Upper 14. Front A-Arm Pivot Shaft 13.
MAINTENANCE Lubrication Recommendations 16. Output shaft support bearing grease fitting Forward 20. Center and Front Eccentrics 19. Swing Arm Bushings 18. Rear Axle Bearing INDEPENDENT REAR SUSPENSION 21. Upper Control Arm 22. Lower Control Arm 87 24. Rear AntiRoll Bar 23.
MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.
MAINTENANCE Steering Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to remove the upper headlight pod. On other models remove the handlebar cover. 2 1 3 4 2. Loosen the four bolts. 3. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right. 4. Torque handlebar adjuster block bolts to 10 to 12 ft. lbs.
MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Model 2X4 4x4 Chain Drive 4x4 Shaft Drive Item Specification Front Spindle Nut(s) 40 Ft. Lbs. Front Wheel Nuts 15 Ft. Lbs. Rear Axle Nut(s) 80 Ft. Lbs. Rear Wheel Nuts 50 Ft. Lbs. Front Spindle Nut(s) Dealer Performed Service Front Wheel Nuts 15 Ft. Lbs. Rear Axle Nut(s) 80 Ft. Lbs. Rear Wheel Nuts 50 Ft. Lbs.
MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension.
MAINTENANCE Optional Suspension Springs Although your Polaris ATV suspension has the capability of providing you with the best ride possible, the following accessory springs are available to better suit your individual riding preference. NOTE: Optional springs may be a different color than standard springs. Owner may paint springs to desired color using Polaris touch up paint, available through your dealer.
MAINTENANCE SOFT FIRM Xpress 300Rear Compression Spring 7041518-067 OPTION 175 lb/in 7041204-157 STANDARD 190 lb/in 7041303-067 OPTION 250 lb/in Xpress 300 Front Strut Spring 7041238-067 OPTION 61 lb/in 7041375-157 STANDARD 64/113 lb/in 7041450-067 OPTION 101 lb/in Magnum 4x4 -Front Strut Spring 7041238-067 OPTION 61 lb/in 7041375-195 STANDARD 64/113 lb/in 7041415-067 OPTION 101 lb/in Magnum 4x4 Rear Compression Spring 7041518-067 OPTION 175 lb/in 7041204-195 STANDARD 190 lb/in 7041303-067
MAINTENANCE Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. Step 1. Pull forward and out to disengage two rear tabs. 2. 3. Place hand on top of side panel behind the fuel tank.
MAINTENANCE Air Cleaner Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Primary Air Filter Box Dual Stage Air Cleaner The Polaris ATV is equipped with a dual stage engine air filtration system. The primary pre-cleaner foam boot is designed to remove the majority of dust particles before they reach the secondary dry filter element. Primary Pre-cleaner Foam Boot Pre-cleaner Boot Inspect the primary air cleaner boot daily or on a regular basis depending on running conditions and dust. 1.
MAINTENANCE Air Cleaner Trail Blazer, Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Secondary (Main) Filter Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine. Secondary filter removal and installation procedure: 1. Remove ATV seat. 2. Remove primary air filter box. 3.
MAINTENANCE Air Filter Service Magnum 2 x 4, Magnum 4 x 4 It is recommended that the air filter be inspected weekly and replaced if dirty. When riding in extremely dusty conditions replacement will be required more often. 1. Lift up on the rear of the seat. 2. Pull the seat back and free of the tabs. NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank. Access Cover 3. Remove the two wing nuts and washers securing the air filter access cover. Access Cover 4.
MAINTENANCE Primary Pre-Filter Service Magnum 2x4 and 4x4 The pre filter should be cleaned before each ride, using the following procedure. 1. Remove pre-filter element. Note position of duct support wire. It must be properly positioned before reinstalling prefilter. 2. Clean the element with high flash point solvent, followed by hot soapy water. 3. Rinse and dry thoroughly. 4. Inspect element for tears or damage. Element Duct Support Wire Must Be Positioned Properly Magnum 2x4 and 4x4 5.
MAINTENANCE Air Filter Service Sport, Scrambler 400 1. Release seat latch and lift up on the rear of the seat. 2. Pull the seat back and free the tab from front cab. 3. Remove the two wing nuts and washers securing the air filter access cover. Access Cover 4. Remove the cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around. 5. Remove the wing nut and washer securing the second cover. The cover should be straight and not distorted. 6.
MAINTENANCE Air Filter Service Trail Blazer 1. Release seat latch and lift up on the rear of the seat. 2. Pull the seat back and free of the tabs. 3. Remove the primary air filter box. 4. Remove the yellow pre-cleaner foam boot, held in place by a gray collar, from the air box. Do not remove the collar. 5. Carefully wash the yellow foam boot in soapy water and dry it. Gray Collar Yellow Boot Intake Silencer Airbox Retainer Airbox Cover Air Filter 6.
MAINTENANCE Air Filter Service Scrambler 500 1. Remove seat. 2. Release clips and remove cover. Main Filter 3. Loosen clamp and remove filter 4. Remove fabric type pre-filter from main filter. Wash pre-filter in soapy water and dry it. Pre-Filter 5. Reinstall pre-filter in main filter. Replace main filter as required. Air Filter Service Sportsman 500, Xplorer 500 1. Remove seat. 2. Remove wingnuts securing the airbox lid and remove lid. Foam Pre--cleaner 3. Pull foam breather filter out.
MAINTENANCE CAUTION: Operation of your ATV without a breather filter can cause engine damage. Breather Filter and Hoses Scrambler 500 WARNING: Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns. 1. Remove heat shield screws and front fender to floorboard screws. Pull fender up and slide heat shield out the front. 2. Reach up under frame rail and remove clamps and filter. 3. Inspect filter for debris.
MAINTENANCE Breather Filter and Hose Sportsman 500, Xplorer 500 1. Remove seat and airbox lid. 2. Locate foam breather filter which is in the front left corner of airbox covering the engine breather hose fitting hole on the front inside of the airbox. 3. Pull filter out and blow off with compressed air. If filter still has debris lodged in the foam, wash in high flash point solvent. Gently squeeze out excess solvent and dry. Do not oil. 4.
MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. Toe Alignment You can check the toe alignment of the vehicle using the following method. The recommended toe alignment is 1/8″ to 1/4″ (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1.
MAINTENANCE Front Brake The front brakes are hydraulic disc type brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and require no adjustment. The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type of driving that has been done. DKeep fluid level in the master cylinder reservoir between the max and min level marks at all times.
MAINTENANCE Rear and Auxiliary Mechanical Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. Wear Line DPads should be changed when worn to 3/64″ (.1 cm) which is about the thickness of a dime. 3/64″ (.1 cm) DInspect the brake disc spline and pad wear surface for excessive wear.
MAINTENANCE Auxiliary Brake Adjustment (Cont.) Polaris ATVs have two different types of auxiliary brake adjustment. Consult your owner’s manual supplement to determine what type your machine has and adjust accordingly. 1. Type I: If adjustment is necessary turn adjuster bolt (A) clockA wise until disc rotation becomes difficult. Turn adjuster bolt counterclockwise until brake engagement starts at approximately 1/2 of the total pedal travel (See Illustration). 2.
MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. Jam Nut 2. Remove electronic throttle control (ETC) cover. 3. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″ (.16 cm) of throttle lever travel before throttle slide starts to open. Adjuster 4.
MAINTENANCE Oil Pump Adjustment Procedure 250 and 300 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. Cable Adjuster 2. Remove electronic throttle control (ETC) cover. Locknut 3. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″ (.16 cm) of throttle lever travel before throttle slide starts to open. 4.
MAINTENANCE Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil reservoir and supply line have been completely run out of oil. In these cases, loosen the pump bleed screw one full turn. Allow oil to flow from the bleed screw for five to ten seconds. Tighten bleed screw. CAUTION: Never run the engine with the bleed screw loose.
MAINTENANCE Engine Choke Adjustment 2 Cycle Engines With the dash mounted choke control toggle flipped to full off position, the choke plunger must be seated on the fuel passageway in the carburetor. If the plunger is not seated on the passageway, the engine will flood or run too rich, causing spark plug fouling and very poor engine performance.
MAINTENANCE Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes. 2. Place the transmission in gear with the parking brake applied. 3. Adjust the carburetor idle screw in or out until the desired idle RPM is reached . Turning the screw in (clockwise) will raise RPM.
MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes. 2. Place the transmission in gear with the parking brake applied. 3. Adjust the carburetor idle screw in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM.
MAINTENANCE Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. 1. Normal The insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded.
MAINTENANCE Transmission Lubrication Transmission Dipstick The transmission dipstick is located on the right side of the machine. The transmission lubricant level should be checked monthly or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick.
MAINTENANCE Front Gearcase Lubrication Sport 500, Xplorer 500, Scrambler 400 Fill plug Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the machine. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. With the ATV on a level surface, remove fill plug and check the lubricant level.
MAINTENANCE Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil should be added or changed as necessary. The oil should be changed annually, especially before off season storage. If the machine is used in wet conditions the oil should be checked more frequently. If the oil has a milky appearance it should be changed as soon as possible.
MAINTENANCE Wheel Removal Front or Rear Wheel Removal Procedure 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 footrest frame as shown. 4. Remove the wheel nuts and remove the wheel. Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub.
MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability. When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect ATV handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. Please refer to your Owner’s Manual Supplement for tire specifications. Minimum Tread Depth 1/8I (.
MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION: Never wash the chain with a high pressure washer or gasoline. Damage to the O-rings will result, causing premature wear and drive chain failure.
MAINTENANCE Adjustment Procedure (cont.) 5. Tighten eccentric clamp bolts to 45 ft. lbs. (6.21 kg/m). Check chain tension. Gen II and III Models 1. Remove cotter pin and washer connecting brake pedal linkage to caliper actuating arm. Remove linkage from arm. 2. Remove right front fender mud flap foot board attaching hardware. 3. Remove center chain guard attaching hardware. Press brake pedal downward and remove guard. 4. Remove forward chain guard attaching bolts and guard. 5.
MAINTENANCE Rear Drive Chain Slack Adjustment CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in illustration. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Collapse the suspension by using an adjustable (buckle type) trailer tie down.
MAINTENANCE Headlight Lamp Replacement WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service while headlight is hot. Serious burns may result. NOTE: Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
MAINTENANCE Headlight Lamp Replacement Trail Blazer, Sport WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service while headlight is hot. Serious burns may result. 1. Remove rubber cap from back of headlight to reveal retention screw. 2. Remove small phillips head screw, and carefully remove bulb from housing.
MAINTENANCE Headlight Lamp Replacement Magnum 2x4, Magnum 4x4, Trail Boss 1. Remove the seat. 2. Remove the plastic panel surrounding the upper portion of the gas tank by first removing the gas tank cap. 3. Remove the Phillips head screws on either side of the panel at the junction of this panel, the lower panels, and the rear of the front fenders. 4. Remove the Phillips head screws on either side of the rear of the upper panel which were revealed by the removal of the seat., and starter pinion 3. & 4. 5.
MAINTENANCE Headlight Adjustment 10. Carefully unplug the socket from the lamp. Remove the panel and set it aside. 11. Replace the oil reservoir cap. 12. Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 13. Disengage the wire bail holding the headlight lamp in place and move it out of the way. 14. Grasp the base of the lamp and lift it out. 15. Reverse the previous steps to replace the lamp and reassemble the panels.
MAINTENANCE Headlight Lamp Replacement Xplorer 400, Xplorer 500, Sportsman 500 Snap pins into tabs Speedometer Cable Position knob in slot and secure in locking tabs Slip O-Ring over pin Adjustment Knob Stop Route plug over handlebar 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access.
MAINTENANCE Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access. 2. Remove three Phillips screws at back of headlight pod. 3. Lift pod cover up. Using a pliers, disconnect speedometer cable. Unplug indicator lights from harness and remove pod cover. O-Ring 4.
MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. Lens Cover 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recommended lamp. 3. Test the taillight/brakelight to see that it’s working. Bulb 4. Reinstall the lens cover removed in step 1. Indicator Lamp Replacement - Style I 1.
MAINTENANCE Cleaning Your 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 If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. Many expensive repair bills can result from using high pressure detergent systems.
MAINTENANCE Storage (Cont.) 7. Drain the recoil housing. 8. Block the ATV so all tires are suspended off the ground. 400 Engines 9. Add Polaris Premium Storage Stabilizer to the fuel tank. 10. Cover the ATV with a canvas cover. Do not use plastic or coated materials since they do not allow ventilation of the vehicle. Remove plug and drain the carburetor Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off. 2.
TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have.
PAINT CODES Model 1998 Trail Boss Item 1998 Scrambler 400 1998 Scrambler 500 1998 Xplorer 500 133 PPG Ditzler No.
PAINT CODES Model 1998 Xplorer 300 1998 Xplorer 400 1998 Sportsman 500 1998 Xpress 300 Item Color Raw Material No. PPG Ditzler No. Springs Fire Red 8520149 72060 Rims Brushed Aluminum N/A N/A Springs Burnished Brown 8520264 N/A Rims Brushed Aluminum N/A N/A Springs Black 8520147 9440 Rims Black 8520147 9440 Springs Bonnie Blue 8520148 12908 Rims Brushed Aluminum N/A N/A Order direct from Midwest Industrial Coatings (612) 934-2852. Mix as directed.
ACCESSORIES Trail Blazer Trail Boss Sport Xpress 300 14 Gallon Sprayer N/A 2871087 N/A 2871087 Boom Mounting Kit N/A 2871340 N/A 2871340 42″ Spray Boom N/A 2871088 N/A 2871088 123″ Spray Boom N/A 2871089 N/A 2871089 Seeder/Spreader, Elec. N/A 2871219 N/A 2871219 Speedometer 2871275 2871275 2871341 2761539 20mph Speedometer N/A N/A N/A N/A Speedometer Protector N/A N/A N/A N/A Elect. Accessory Brd.
ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 2871087 N/A N/A 2871087 2871087 2871087 2871340 N/A N/A 2871340 2871340 2871340 2871088 N/A N/A 2871088 2871088 2871088 2871089 N/A N/A 2871089 2871089 2871089 2871219 N/A N/A 2871219 2871219 2871219 STD TBA TBA 2871539 STD 2871789 2871085 N/A N/A N/A 2871353 N/A 2871316 N/A N/A N/A N/A N/A 2871802 2871802 2871802 N/A N/A N/A 2871441 2871442 2871441 2871442 2
ACCESSORIES Trail Blazer Trail Boss Sport Xpress 300 Gun Scabbard N/A 2870854 N/A 2870854 CV Protector N/A N/A N/A N/A Rack Bag, Large, Black N/A N/A N/A 2871787 Rack Bag, Gray/Black N/A N/A N/A 2871216 Rack Bag, Camo N/A N/A N/A 2871506 Dual Headlights 2871490 N/A 2871490 STD K&N Air Filter 2871509 2871509 2871508 2871509 Cover, Red/Blue 2870796 2870796 2870796 2870796 Cover for ATV w/windshield Red/Blue N/A 2871313 N/A 2871313 Cover, Camo 2871084 2871084
ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 2870854 N/A N/A 2870854 2870854 N/A N/A 2871234 2871234 2871234 2871234 STD 2871787 N/A N/A 2871787 2871787 2871787 2871216 N/A N/A 2871216 2871216 2871216 2871506 N/A N/A 2871506 2871506 2871506 2870936 STD STD STD STD STD 2871508 2871508 2871786 2871509 2871509 1871786 2870796 2870796 2870796 2870796 2870796 2870796 2871313 N/A N/A 2871313 2871313 2871313 28710
ACCESSORIES Trail Blazer Trail Boss Sport Xpress 300 Rear Rack Kit 2871357 STD 2871357 STD Front Rack Extender 3.5″ N/A 2871502 N/A 2871499 Front Rack Extender 8″ N/A N/A N/A 2871318 Rear Rack Extender 3.
ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 STD 2871357 2871357 STD STD STD 2871502 N/A N/A 2871499 2871499 2871499 2870931 N/A N/A 2871318 2871318 2871318 2871503 N/A N/A 2871501 2871501 2871501 2870942 N/A N/A 2871319 2871319 2871319 2871315 2871315 2871315 2871427 2871427 2871427 140
ACCESSORIES Magnum 4x4 Sportsman 500 14 Gallon Sprayer 2871087 2871087 Boom Mounting Kit 2871340 2871340 42″ Spray Boom 2871088 2871088 123″ Spray Boom 2871089 2871089 Seeder/Spreader, Elec. 2871219 2871219 Speedometer STD STD 20mph Speedometer 2871085 2871353 Speedometer Protector 2871316 N/A Elect. Accessory Brd.
ACCESSORIES Magnum 4x4 Sportsman 500 Rear Rack Kit STD STD Front Rack Extender (3.
ACCESSORIES Magnum 4x4 Sportsman 500 Accessory Winch Kit 2871461 2871461 Front Rack Kit STD STD Front Rack Extender 8″ 2870931 2871318 Rear Rack Extender 3.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441--5078, 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.
WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
INDEX Engine Cooling System . . . . . . . . . . 45-47 Accessories . . . . . . . . . . . . . . . . . 135-143 Air Box Drain . . . . . . . . . . . . . . . . . . . . . 98 Air Cleaner . . . . . . . . . . . . . . . . . . 95-101 Air Filter Service, Magnum . . . . . . . . . 97 Air Filter Service, Sport, Scrambler 400 . . . . . . . . . . 99 Air Filter, Trail Blazer . . . . . . . . . . . . . 100 Air Filter, Scramblert 500 . . . . . . . . . . 101 Air Filter, Sportsman 500, Xplorer 500 . . . . . . . . . . . . . . . . .
INDEX Throttle Lever . . . . . . . . . . . . . . . . . . . . 38 Tire Inspection . . . . . . . . . . . . . . . . . . . 119 Toe Alignment . . . . . . . . . . . . . . . . . . . 104 Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Torque Specifications . . . . . . . . . . . . . . 90 Trail Obstacles . . . . . . . . . . . . . . . . . . . 70 Transmission Gear Selector Operation . . . . . . . . . . . . . . . . . . . 42 Transmission Lubrication . . . . . . . . . .
