WARNING The engine exhaust from this product contains chemicals known to the State of California 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.
Visit us at www.polarisindustries.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2006 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.
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 Know Your Vehicle . . . . . . . . . . . . 6 Emission Control Systems . . . . . 95 Safety Decals . . . . . . . . . . . . . . . . 8 Maintenance . . . . . . . . . . . . . . . . 97 Safety . . . . . . . . . . . . . . . . . . . . . 12 Specifications . . . . . . . . . . . . . . 186 Features and Controls . . . . . . . . 50 Polaris Products . . . . . . . . . . . . 188 Break-In Period. . . . . . . . . . . . . . 70 Troubleshooting. . . . . . . . . . . . . 190 Pre-Ride Inspection . . . . . .
Know Your Vehicle As the operator of the vehicle, you are responsible for your personal 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 vehicle, including safe operating procedures. Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place.
Know Your Vehicle Vehicle Identification Numbers 1 2 Vehicle Model Number: ____________________________________________________________________ Frame Vehicle Identification Number (1): ______________________________________________________ Engine Serial Number (2):__________________________________________________________________ Key Number (on the key): __________________________________________________________________ 7
Safety Decals Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle. If any decal becomes Age 16 Discretionary illegible or comes off, Warning Warning contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
General Warning WARNING Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear. Never use on public roads. Never carry passengers. Never use with drugs or alcohol.
Safety Decals Age 16 Warning Discretionary Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flipover on hilly terrain, use throttle and brakes gradually. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.
Safety Decals No Passenger Warning Tire Pressure/Load Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 4 (27.6) MAXIMUM WEIGHT CAPACITY 215 LBS. (97.5 KG) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo.
Safety 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. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
Riding Gear Safety Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
Safety Operator Safety WARNING Failure to follow the warnings in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm. You were also provided with printed materials that explain safe operating procedures.
Safety Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. 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 injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Safety Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow all operating procedures. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and age eligible family members are entitled to take the ATV RiderCoursesm.
Safety Operator Safety • Never operate an ATV on a public street, road or highway, including a dirt or gravel road. • 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. • Never consume alcohol or drugs before or while operating an ATV. • Never operate at excessive speeds.
Operator Safety • Never operate on excessively rough, slippery or loose terrain. • 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. • Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
Safety Operator Safety • Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose surfaces. Shift your weight uphill. 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. 20 • Always use proper procedures if you stall or roll backwards while climbing a hill.
Operator Safety • Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control. • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Safety • Avoid operating the ATV through deep or fast-flowing water.
Safety Operator Safety • Always check for obstacles or people behind the ATV before operating in reverse. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure. • Never modify an ATV through improper installation or use of accessories. • Never exceed the stated load capacity for your ATV.
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 ATV RiderCoursesm offered by Polaris through the SVIA.
Safety Operator 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.
Safety Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may 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.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator's chance of losing control of the ATV, which can result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that's proper for the terrain, visibility and operating conditions, and your experience. 32 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.
Safety Operator Safety WARNING POTENTIAL HAZARD Attempting 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 jumps or other stunts. Avoid exhibition driving.
Safety Operator Safety WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV. WHAT CAN HAPPEN A wagon, sled or other object towed behind an ATV does not have brakes or steering. The object may overturn or collide with other objects and cause serious injuries. HOW TO AVOID THE HAZARD Never tow or pull an object behind the ATV.
Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.
Safety Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds.Never turn at excessive speed. WARNING POTENTIAL HAZARD Improperly operating in reverse.
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 contact the rear wheels and lead to accident or injury.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees 25°.
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 beginning on page 82. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25 degrees 25°. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
Safety Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 88. 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 try 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 86. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
Safety Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill. Apply the front brakes gradually (right lever). When fully stopped, apply the foot brake as well and then lock the parking brake. If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power.
Safety Operator Safety WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control. 44 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn.
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 Operating this ATV with improper tires, or with improper or uneven tire pressure.
Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
Safety Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo. WHAT CAN HAPPEN Overloading or carrying/towing cargo can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never haul cargo or tow a load with this ATV. Never exceed the stated load capacity for this ATV. WARNING POTENTIAL HAZARD Operating the ATV with improper modifications.
Safety Operator Safety WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death. 48 WARNING Operating a damaged ATV can result in an accident with serious injury or death.
Safety Operator Safety WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass. WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death.
Features and Controls Main Key Switch Engine Stop Switch 50 Start Button
Main Key Switch Features and Controls The main key switch must be in the RUN position to start the engine. See page 75 for starting procedures. Start Button Press the start button to engage the starter. Always release the start button promptly when the engine starts. NOTE: If the starter fails to engage, replace the blown fuse or see your Polaris dealer. Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly.
Features and Controls Lights Indicator Lights An illuminated light in the indicator window will alert you to the following conditions. • Hot engine • Reverse gear is selected • Neutral gear is selected NOTE: If indicator lights fail to oper- ate, check connections. See your Polaris dealer for inspection of the capacitor and voltage regulator.
Features and Controls Lights Headlights WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. This vehicle is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Use the light switch to turn the lights on and off and to switch the lights from high beam to low beam.
Features and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar. Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears. The clutch is self-adjusting, but lever position can be changed to fit the operator’s hand. Turn the adjusting knob counterclockwise to move the lever closer to the handlebar. Turn the adjusting knob clockwise to move the lever away from the handlebar.
Clutch Fluid The clutch fluid master cylinder is located on the left handlebar. Check the fluid level in the reservoir before each ride. The level should be 4mm below the upper edge of the reservoir. Do not overfill. Polaris recommends the use of KTM Hydraulic Clutch Oil. Do not use brake fluid. Do not mix clutch fluid with any other hydraulic fluids. See page 188 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2.
Features and Controls Throttle Lever WARNING Operating with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate the vehicle with an 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.
Features and Controls Throttle Lever This ATV is equipped with an 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. 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 The foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. 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 under the seat. Maintain the fluid level between the minimum and maximum marks. Check the rear brake light for proper operation before each use of the vehicle.
Features and Controls Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar. Squeeze the brake lever toward the handlebar to engage the front brakes. These 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. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding.
Features and Controls Master Cylinder/Brake Fluid 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. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
Master Cylinder/Brake Fluid Features and Controls Check the brake fluid in the master cylinder before each ride. If the fluid level is low add DOT 4 brake fluid only. Do not overfill. See page 188 for the part numbers of Polaris products. NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. Hand Brake Fluid Level View the fluid level through the indicator window on the side of the master cylinder.
Features and Controls Parking Brake 1. Place the transmission in first gear. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock down to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. The lock will automatically disengage. Unlocked Locked WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death.
Parking Brake Important Safeguards • The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. • 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. Features and Controls • Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling. • Place the transmission in first gear before locking the parking brake.
Features and Controls Manual Shift 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 65.
Manual Shift Features and Controls 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: Do not squeeze the throttle lever. 3. 4. 5. 6. 7. 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.
Features and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally. 1. Place the transmission in first gear. See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3. Shift down into reverse gear. NOTE: 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 vehicle, 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.
Features and Controls Choke Choke Knob The choke assists in starting a cold engine. The choke knob is located on the left side of the carburetor. Refer to the engine starting procedure on page 75 for correct choke and throttle settings during starting. Fuel Tank The fuel tank filler cap is located directly below the handlebar. Polaris recommends the use of 91 octane or higher fuel. Do not use E-85 fuel. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter.
Fuel Valve Features and Controls The fuel valve is located 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. Always return the valve to the ON position after refueling.
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 ATV is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the break-in period with an additional 12 hours of cautious operation, with engine speed below 75% of capacity.
Break-In Period 1. Fill the fuel tank with gasoline. See page 74. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 109. 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 throttle positions. Do not operate at sustained idle. 6.
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 Inspection Pre-Ride Checklist Coolant (if applicable) Ensure proper level Page 119 Coolant hoses (if applicable) Inspect for leaks -- Throttle Ensure smooth operation 56 Indicator lights / switches Ensure operation Engine stop switch Ensure proper operation 52, 53 51 Air filter Inspect, clean, replace as needed 122 Air box sediment tubes Drain deposits when visible Headlamp Check operation, apply Polaris dielectric grease to the socket when the lamp is replaced 129 Brake light
Operation Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck.
Operation Starting the Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the throttle lever while starting the engine. Do not depress the throttle lever when the engine is stopped.
Operation Starting the Engine 1. 2. 3. 4. 5. 6. Shift the transmission to neutral. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle. Disengage the clutch. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine. 7. Move the engine stop switch to the RUN position. 8. Turn the ignition key to ON.
Starting the Engine Operation NOTE: If starting the engine while in gear, apply the hand brake and squeeze the clutch lever fully to disengage the clutch. 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 64. 9. 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.
Operation Driving Procedure 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. 3. Shift the transmission into gear. See page 64. 4. Check your surroundings and determine your path of travel. 5. Release the parking brake. 6. Slowly depress the throttle with your right thumb while slowly releasing the clutch lever to begin driving. 7. Drive slowly. Practice maneuvering and using the throttle, clutch and brakes on level surfaces.
Operation Making Turns Practice making turns at slow speeds before attempting to turn at faster speeds. WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury or death. Avoid turning at sharp angles. Never turn at high speeds. Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times.
Operation Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution, especially when downshifting.
Driving on Slippery Surfaces Operation 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 Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual.
Operation Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25° maximum). 3. Keep both feet on the footpegs. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
Operation Driving Across Hillsides 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.
Driving Across Hillsides Operation If you enter into a situation where sidehilling is unavoidable, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keeping your feet on the footpegs. 3. Steer slightly into the hill to maintain direction.
Operation 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.
Turning Around on a Hill Operation 6. Reach across the handlebar and apply the front brakes to unlock the parking brake. 7. With the front brakes applied, pull in the clutch 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. 8 ft. (2.4 m) 8. With the front brakes still applied, release the clutch lever and lock the parking brake. Remount from the uphill side, keeping body weight uphill. 9.
Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive 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.
Parking on a Hill or Incline Operation Avoid parking on a hill or 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. Turn the fuel valve off.
Operation Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs. 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 obstacles if possible. 4. After driving through water, dry the brakes by applying light pressure to the lever (while moving) until braking action is normal.
Operation Driving Through Water Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in deeper water than recommended, it's critical to have it serviced as outlined in the maintenance chart beginning on page 97. Engine oil and all grease fittings need special attention. 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.
Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always look left, right and behind the ATV before backing.
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. Follow the reverse operation procedures outlined in this manual. This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.
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.
Noise Emission Control System Emission Control Systems Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
Emission Control Systems Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition.
Periodic Maintenance Chart Maintenance The high performance engine in your vehicle requires routine service to maintain the highest level of performance and reliability. Please read and follow the “Break-In Period” and “Maintenance” sections of your Owner’s Manual carefully. Failure to perform the recommended procedures at the service intervals specified in your owner’s manual will void warranty coverage and decrease the performance and reliability of your vehicle.
Maintenance Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often under severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services.
Maintenance Periodic Maintenance Chart Item Brake systems/brake fluid Tires Wheels/lug nuts Frame fasteners Coolant Fuel Engine oil Transmission oil Throttle Clutch system/clutch fluid Lights Engine stop switch Steering 100 Maintenance Interval (whichever comes first) Hours -------------- Calendar Pre-ride Fuel Used -------------- Remarks Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist.
Maintenance Periodic Maintenance Chart Item E X E Q z Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Boots Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Maintenance Interval (whichever comes first) Hours Calendar ------- Pre-ride Post-ride ------- 3 Break-in 5 (20) Remarks Fuel Used See Page in gallons (liters) Check each day before operating the vehicle. Make adjustments as needed.
Maintenance Periodic Maintenance Chart Item XE X X E E 102 Maintenance Interval (whichever comes first) Hours Calendar Brake pad wear Battery Air filter Oil and filter change 10 10 15 15 Monthly Monthly Weekly 6M ---26 (100) Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Clutches Spark plug 15 15 15 15 30 30 6M 6M 6M 6M 6M 6M 26 (100) 26 (100) 26 (100) 26 (100) 52 (200) 52 (200) Remarks Fuel Used See Page in gallons (liters) Inspect regularly Check terminals; clean
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar General lubrication 45 3M 78 (300) Carburetor float bowl 45 6M 78 (300) QE X Throttle cable/ETC switch Drive chain(s) 45 45 6M 6M 78 (300) 78 (300) XQ Brake pad replacement Coolant strength 45 45 6M 6M 78 (300) 78 (300) Xz X E Q z Remarks Fuel Used See Page in gallons (liters) Lubricate all fittings, pivots, cables, etc.
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Xz Upper steering post (1) 45 6M -- Xz Xz Front A-Arms (2) Rear Control Arm Bushings (3) Stabilizer Bar (4) Rear Control Arm Needle Bearings (5) 45 45 6M 6M --- 45 90 6M 12 M --- Xz Xz 2 1 104 5 2 3 5 Remarks Inspect; tighten fasteners; grease after washing ATV/driving in water Inspect; tighten fasteners; grease (also after washing ATV or driving in
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Clutch springs Cam chain tensioner Coolant system Cooling system hoses Radiator 60 60 90 90 90 12 M 12 M 12 M 12 M 12 M 104 (400) 104 (400) 156 (600) 156 (600) 156 (600) QE Fuel system 90 12 M 156 (600) E Cylinder and piston 90 -- 156 (600) Piston pin circlip groove 90 -- 156 (600) X X E Q z Remarks Fuel Used See Page in gallons (liters) Check spring length (see dealer) Check r
Maintenance Periodic Maintenance Chart Item E E E E E E E E 106 Maintenance Interval (whichever comes first) Remarks Hours Calendar Fuel Used Compression ring Oil scraper ring 90 90 --- 156 (600) 156 (600) Camshaft Valve spring cap Camshaft bearings Valve springs Valve seats/guides Rocker arm rollers Timing chain Cam chain tensioner Bearings (connecting rod, balance shaft, crankshaft main) Crankshaft run-out 90 90 90 90 90 90 90 90 90 ---------- 156 (600) 156 (600) 156 (600) 156 (600) 156 (
Maintenance Periodic Maintenance Chart Item QE QE Q Q Q Hours Calendar Oil pressure valve Transmission 90 90 --- Ignition Timing Clutch fluid Jet needle/needle jet Brake fluid Spark arrestor Front/rear wheel bearings Toe adjustment -90 180 180 300 300 Headlight aim X E Q z Maintenance Interval (whichever comes first) Remarks Fuel Used See Page in gallons (liters) 156 (600) 156 (600) 12 M 12 M 24 M 24 M 36 M 36 M As required As required ------- Measure spring; replace as needed Check entir
Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. See page 188 for the part numbers of Polaris products. NOTE: Do not use Polaris PS-4 Performance Synthetic 10W-40 Oil. Always use 2W-50.
Engine Oil Level Check the oil level before each use of the vehicle. If the engine is cold, the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible at the upper edge of the sight glass. 1. Position the vehicle on a level surface. 2. View the oil level through the sight glass on the right side of the vehicle. 3. Remove the fill plug and add the recommended oil as needed. 4. Reinstall the fill plug.
Maintenance Engine Oil 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 filters within a few hours of draining the oil. Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Perform the initial break-in oil change after the first three hours of operation.
Maintenance Engine Oil Change 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain completely. CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. 4. Clean the crankcase sealing surface and the drain plug (with magnet) thoroughly. 5. Replace the sealing ring. Reinstall the drain plug. Torque to 15 ft. lbs.
Maintenance Engine Oil Change Cleaning the Short Oil Screen Hex Plug Front Short Screen View from bottom of vehicle 112
Engine Oil Change Maintenance Cleaning the Short Oil Screen 1. Insert a hex key into the plug at the bottom of the engine. See illustration on preceding page. 2. Using a hammer, tap lightly on the key a few times to loosen the seal. Remove the plug. 3. Remove the short oil screen. Clean the screen components thoroughly and blow well with compressed air. 4. Check the O-rings. If damaged, install new O-rings. 5. Reinstall the screen to the plug. 6. Lubricate the threads and reinstall the plug. Torque to 7.
Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen plug, located on the side of the engine near the engine number. 2. Remove the oil screen. Clean the screen thoroughly and blow with compressed air. 3. Check the O-rings. If damaged, install new O-rings. 4. Place the long oil screen on a pin-type key or similar tool of about 12 inches (300 mm) in length.
Maintenance Engine Oil Change Cleaning the Long Oil Screen CAUTION An improperly installed oil screen will function poorly and result in increased engine wear. Install the screen securely at the angle shown in the illustration. 5. Insert the tool through the opening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. 6. Reinstall the plug. Torque to 11 ft. lbs. (15 Nm).
Maintenance Engine Oil Change Changing Oil Filters 1. Place a drain pan under the engine. 2. Remove the four oil filter cover screws (1). Remove the covers. 3. Using circle clip (snap ring) pliers, pull the oil filter inserts (2) out of the housing. 4. Thoroughly clean the engine casing, filter covers and sealing surfaces of the O-rings. Check the O-rings. If damaged, install new O-rings. 5. Fill each oil filter with oil. Install the long filter at the front of the filter box.
Maintenance Engine Oil Change Changing Oil Filters 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. Tighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fill plug (4). Add 40 oz. (1.2 liters) of the recommended engine oil (see page 108). Reinstall the fill plug. 9. Start the engine. Allow it to idle for at least one minute to fully distribute the new oil. Stop the engine. 10. Check for leaks at all threaded connections and at the oil filter covers. 11.
Maintenance Engine Cooling System 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.
Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL and ADD marks on the side panel (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.
Maintenance Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level If the recovery bottle has run dry, inspect the level in the radiator and add coolant if necessary. The radiator pressure cap is located on the left side of the vehicle. 1. Remove the pressure cap. 2. Using a funnel, slowly add coolant as necessary through the radiator filler neck. 3.
Engine Cooling System Maintenance Cooling System Bleeding Bleeding the cooling system is required only if the system has been drained for maintenance and/or repair. Always allow the engine to cool sufficiently before removing the radiator pressure cap. 1. Remove the pressure cap. 2. Using a funnel, slowly add the recommended coolant. Fill the radiator to the bottom of the filler neck. 3. Reinstall the pressure cap. 4.
Maintenance Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover. 3. Loosen the filter clamp. 4. Remove the air filter. 5. Remove the inner and outer foam filter elements from the internal cage.
Air Filter Systems 6. 7. 8. 9. Maintenance Wash the filters in soapy water, then rinse and let dry. Apply a commercially available foam filter lubricant to the foam filters. Reinstall all components. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.
Maintenance Carburetor Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and the needle jet after every 180 hours of operation. Idle Speed Carburetor idle adjustments affect engine starting behavior. A proper idle speed of 1500-1600 RPM will result in easier starting. If idle speed is unsatisfactory, use the following procedure to make adjustments. 1. Position the vehicle on a level surface. 2. Lock the parking brake.
Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. Turn the fuel valve off. 2. Place a suitable container under the carburetor to collect drained fluid. 3. Remove the hex plug (1). Allow fluids to drain. 4. Reinstall the hex plug securely.
Maintenance Carburetor Jetting 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 (305 m) increase in elevation.
Maintenance 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. Do not service the headlamps until they've cooled sufficiently.
Maintenance Lights Headlight Adjustment 1. Position the vehicle 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 cm) below the mark placed on the wall.
Maintenance Lights 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 to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb. 3. Apply dielectric grease to the socket and install the new bulb. Rotate firmly. Left Lamp Counterclockwise Right Lamp Clockwise NOTE: The bulb must be positioned so the harness installs into the lamp at outer side. 4.
Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp. 5. Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab.
Lights Maintenance Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. 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. 7. Install the adjusting screw, leaving it loose so the headlight can be adjusted. 8. Reinstall the front cab. Connect the wire harness to the headlamp. 9.
Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle. 1. Turn the ignition key on. 2. Lightly apply and release the foot brake several times. A properly operating rear brake light will immediately flash on and off with each movement of the brake pedal. 3. If the light does not operate properly, grasp the switch body with a pliers or similar tool and hold it lightly, but securely.
Maintenance Front Cab Removal 1. Remove the left and right cab mount screws (1). 2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2). 4. Remove the four side panel screws (3). 5. Gently pull the cab upward to disengage it from the stand-off. Place the cab upside down on a soft protective surface to prevent scratching.
Maintenance Side Panel Removal 1. 2. 3. 4. 134 Unlatch and remove the seat. Remove the front cab. Remove the two screws securing the side panel. Remove the side panel.
Maintenance Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove the cab.
Maintenance Spark Plugs Refer to the specifications section beginning on page 186 for recommended spark plug type and gap. 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. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
Spark Plugs Maintenance Normal Plug 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 carburetor/throttle body adjustments. Wet Fouled Plug The wet fouled insulator tip is black.
Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right side of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm).
Maintenance Spark Arrestor Clean-Out To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 97. WARNING Failure to heed these warnings could result in serious injury or death. 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.
Maintenance Spark Arrestor Clean-Out 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. NOTE: If necessary, blow debris from the screen with compressed air.
Spark Arrestor Clean-Out Maintenance 3. Inspect the screen for wear and damage. Replace a worn or damaged screen. 4. Remove and inspect the gasket (4). Replace a worn or damaged gasket. 5. Reinstall the gasket and arrestor. Torque screws to 50 in. lbs. (5.6 Nm).
Maintenance 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.
Maintenance Vehicle Immersion 1. 2. 3. 4. Turn the fuel valve off. Drain water from the air box and clean the air filter. See page 122. Drain the carburetor bowl. See page 125. Remove the spark plug. See page 138. 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.
Maintenance Vehicle Immersion 6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride inspection level, water has entered the crankcase. Do not start the engine. Transport the vehicle to your dealer for inspection and service.
Maintenance 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 the 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.
Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery Removal 1. 2. 3. 4. 5. 146 Remove the front cab (see page 133). Disconnect the hold-down strap securing the battery in position. Disconnect the black (negative) battery cable first.
Battery Installation Maintenance NOTE: Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger. 1. 2. 3. 4. 5. 6. Place the battery in the battery holder. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Attach the hold-down strap. Reinstall the front cab.
Maintenance Battery Charging (Sealed Battery) On a sealed battery, 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. The battery may be recharged without removing it from the vehicle. Use the remote charging terminals under the right front cab.
Battery Charging (Sealed Battery) Maintenance When using an automatic charger such as the Polaris Battery Tender, refer to the manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging. WARNING An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
Maintenance Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.
Maintenance 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 decal on your ATV 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" (3 mm) or less.
Maintenance Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance. Bolt Location & Size Torque Specification Front 3/8" 30-35 ft. lbs. (40-47 Nm) Rear 3/8" 30-35 ft. lbs. (40-47 Nm) Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. 2. 3. 4. 152 Stop the engine. Place the transmission in gear.
Maintenance Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Never install the rim with the valve stem to the inside of the vehicle. Always ensure that all nuts are torqued to specification. 1. Place the transmission in gear. Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. 3.
Maintenance Boot Inspection Before Operating Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, see your Polaris dealer for service or replacement. After Operating Inspect the boots after operating the vehicle. If a boot is bulging or ballooned, perform the boot burping procedure on page 155.
Maintenance Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape (2). 3. Wipe excess grease from the shaft before returning the boot to the boot groove. Use caution not to allow excess air back into the system when reinstalling the boot.
Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system. See page 55. 1. Position the vehicle on a level surface. Turn the handlebar until the master cylinder is in a horizontal position. 2. Remove the two cover screws, the cover and the rubber boot. 3.
Clutch System Bleeding Maintenance 4. Remove the bleeder screw (2) from the slave cylinder. 5. Press fluid into the system until the fluid runs out of the hole (3) in the master cylinder without producing bubbles. NOTE: Extract fluid from the master cylinder during the process to prevent overflowing. 6. When finished, remove the bleeder syringe. 7. Reinstall the bleeder screw. 8. Add or remove fluid as needed to maintain the level 4mm below the top edge of the master cylinder reservoir. 9.
Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are needed, use the procedure on page 159. 1/16" - 1/8" (1.
Maintenance Throttle Cable Freeplay Adjustment 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. 1. Locate the throttle cable at the handlebar. 2.
Maintenance Brakes WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill. Both brakes are self-adjusting, but the following checks are recommended to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation.
Brakes Maintenance 1. Always maintain brake fluid at the recommended level. See pages 60-61. 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 mm).
Maintenance Toe Alignment 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. Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position.
Maintenance Toe Alignment 4. Tie an elastic string 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. 5. Measure the distance between the string in front of the rear tires (1) and in front of the front tires (2). If the two measurements are not equal, adjust the string position until the measurements are equal. 6.
Maintenance 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. Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. At the center point of the top side of the chain there should be 1/4"-3/8" (6-9 mm) deflection. Use the procedure on the following page if the chain needs adjustment.
Maintenance Chain Tension 1. Loosen the upper and lower pivot mounting bolts (1). 2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4. Torque the chain adjusting bolt to 17 ft. lbs. (23 Nm).
Maintenance Handlebar Adjustment WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference. 1. Loosen the four handlebar bolts. 2. Adjust the handlebar to the desired height.
Steering Inspection Maintenance Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the steering post, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.
Maintenance Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of the lower front bumper bolt. Note this measurement for later use. 5. Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars.
Front Suspension Maintenance Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. Subtract the step 8 measurement from the step 4 measurement. The difference should be between 3.75 and 4 inches (9.5-10.2 cm). 9. If the number is less than 3.
Maintenance Front Suspension 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. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments.
Maintenance Front Suspension Spring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring clockwise to increase preload (1). Turn the ring counter-clockwise to decrease preload (2).
Maintenance Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the rear of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of the rear lower control arm pivot bolt. Note this measurement for later use.
Rear Suspension Maintenance Suspension Set-Up 5. Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. 9. Subtract the step 8 measurement from the step 4 measurement.
Maintenance Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the softest position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments.
Maintenance 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 vehicle off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring clockwise (1) to increase preload. Turn the ring counter-clockwise (2) to decrease preload.
Maintenance Rear Suspension Compression Damping The compression damping clickers are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From this position, turn the screw clockwise to increase compression damping.
Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
Maintenance Cleaning Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots. Washing Tips • • • • Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle.
Cleaning Maintenance Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: • Wheel bearings • Brakes • Electrical components and wiring • Cab and body panels • Transmission seals • Labels and decals NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement.
Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.
Maintenance Storage CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and clean the vehicle as recommended. See page 177. Battery Storage Refer to pages 145-150 for battery storage and battery charging procedures.
Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 110. Air Filter / Air Box Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 97.
Storage Maintenance Stabilize the Fuel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. It also prevents bacterial growth and promotes better starting after the storage period. 3.
Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground. 4. Cover the vehicle with an appropriate cover. NOTE: Do not use plastic or coated materials.
Transporting the ATV Maintenance Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Remove the key to prevent loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. Turn the fuel valve off. 7. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.
Specifications Outlaw 525 Max. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity 215 lbs./97.5 kg 395 lbs./179 kg 3.9 gal./14.8 l 71.5 in./182 cm 47.5 in./121 cm 45 in./114 cm 51 in./130 cm 11.5 in./29 cm 67 in./170 cm 1.9 qts./1.
Specifications Outlaw 525 Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio - Reverse Rear Two-Wheel Drive 5-Speed Manual Shift 2.516 2.500 1.941 1.579 1.333 1.130 2.429 Tire Size - Front Tire Size - Rear Tire Pressure - All Front Brake Rear Brake Parking Brake Headlights Taillights Brakelight 21 x 7R10 20 x 10R9 4 psi/27.
Polaris Products Part Number 2876244 2876245 2871312 2871322 2871423 2871460 2871329 2872073 2872348 1350046 188 Description Engine Lubricant PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Grease / Specialized Lubricants Grease Gun Kit, Premium All Season (3 oz.) Premium All Season Grease (3 oz. cartridge) Premium All Season Grease (14 oz. cartridge) Starter Drive Grease (2 oz.) Dielectric Grease (Nyogelt) Chain Lube, Aerosol (6.25 oz.
Polaris Products Part Number 2871323 2871534 2871326 2870652 2872189 2876335 2872893 Description Coolant 60/40 Coolant (gal.) 60/40 Coolant (qt.) Additives / Miscellaneous Carbon Clean Plus (12 oz.) Fuel Stabilizer (16 oz.) DOT4 Brake Fluid (12 oz.) Hydraulic Clutch Oil (qt.) Engine Degreaser (12 oz.
Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts.
Troubleshooting Engine Turns Over, Fails to Start Possible Cause Solution No spark to spark plug Inspect, clean and/or replace spark plugs See your Polaris dealer Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart. If engine fails to start, inspect, clean and/or replace spark plugs. Low battery voltage Recharge battery to 12.
Troubleshooting Engine Doesn’t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12.
Troubleshooting 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 or non-recommended fuel Replace with new fuel Exhaust leak Inspect system for leaks; see your Polaris dealer Incorrectly installed spark plug wire See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer 193
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Defective ignition system See your Polaris dealer Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Incorrect idle adjustment Adjust idle speed or see your Polaris dealer Clogged idle jet Disassemble carburetor and clean the jets Other mechanical failure See your Polaris dealer 195
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 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 Repl
Troubleshooting Engine Fails to Reach High RPM Possible Cause Solution Worn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets Tighten jets Faulty ignition timing See your Polaris dealer Engine Uses Excessive Oil Possible Cause Solution Bent engine ventilation hose Install a new hose Excessive oil in system Check oil level, maintain at recommended level Use of non-recommended oil (too thin) Replace with a recommended oil 197
Troubleshooting Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn the fuel valve to reserve, refuel Interrupted fuel supply Clean fuel system and carburetor Clogged, dirty or wet air filter Inspect and clean or replace Electronic throttle control 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 198
Troubleshooting Engine Stops or Loses Power Possible Cause Solution 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 connections Check all connections and tighten Low bat
Troubleshooting Engine Overheats Possible Cause Solution Debris lodged in screen Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radiator fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency.
Troubleshooting Engine Fails to Reach Full Power Possible Cause Solution Interrupted fuel supply Clean fuel system and carburetor Float leaks Replace the float Clogged, dirty or wet air filter Inspect and clean or replace Faulty exhaust system Check system for damage; see your Polaris dealer Valve gap is too small Adjust valve gap Faulty ignition timing See your Polaris dealer 201
Warranty LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES 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.
Warranty HOW TO OBTAIN WARRANTY SERVICE 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.
Warranty EXPORTED VEHICLES 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.
Warranty U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
Maintenance Log DATE SERVICE INTERVAL (HOURS) 60 90 212 TECHNICIAN SERVICE PERFORMED / COMMENTS
Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 213
Maintenance Log DATE 214 SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS
Index A Age Restrictions . . . . . . . . . . . . . . 14 Air Filter Systems . . . . . . . . . 122-123 Arrestor, Spark . . . . . . . . . . . 140-141 B Battery Charging. . . . . . . . . . . . 148-150 Installation . . . . . . . . . . . . . 147 Maintenance. . . . . . . . . . . . 145 Removal . . . . . . . . . . . . . . . 146 Storage . . . . . . . . . . . . 146, 181 Bleeding the Cooling System . . . 121 Boots . . . . . . . . . . . . . . . . . . . . . . . 13 Brake Fluid . . . . . . . . . . . . . . . .
Index F Fluid Brake . . . . . . . . . . . . . . . . 60-61 Clutch . . . . . . . . . . . . . . . . . . 55 Foot Brake . . . . . . . . . . . . . . . . . . . 58 Foot Brake Fluid Level . . . . . . . . . 61 Fuel Filter . . . . . . . . . . . . . . . . . . . . 68 Fuel Stabilizer . . . . . . . . . . . . . . . 183 Fuel System . . . . . . . . . . . . . . . . . . 74 Fuel Tank . . . . . . . . . . . . . . . . . . . . 68 Fuel Valve . . . . . . . . . . . . . . . . . . . 69 G Gloves. . . . . . . . . . . . . . . . . . . .
Index R Restrictions . . . . . . . . . . . . . . . . . . 14 Reverse Lock-Out Switch . . . . . . . 66 Riding Gear. . . . . . . . . . . . . . . . 12-13 S Safety Decals Age 16 Warning. . . . . . . . . . 10 Discretionary Warning. . . . . 10 General Warning . . . . . . . . . . 9 No Passenger Warning. . . . . 11 Sport ATV Warning. . . . . . . 10 Tire Pressure/Load Warning 11 Safety Training . . . . . . . . . . . . . . . 15 Severe Use . . . . . . . . . . . . . . . . . . 98 Shift Pedal. . . . . . . . . . . . . .
