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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
WARNING NEVER operate: 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 without proper training or instruction at speeds too fast for your skills or the conditions on public roads - a collision can occur with another vehicle with a passenger - passengers affect balance and steering and increase risk of losing control NEVER USE WITH DRUGS OR ALCOHOL READ OWNER'S MANUAL.
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POLARIS, THE WAY OUT and OUTLAW are registered trademarks of Polaris Industries Inc. Copyright 2009 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 Introduction . . . . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . 168 Safety . . . . . . . . . . . . . . . . . . . . . 10 Polaris Products . . . . . . . . . . . . 172 Features and Controls . . . . . . . . 38 Troubleshooting. . . . . . . . . . . . . 174 Operation . . . . . . . . . . . . . . . . . . 58 Declaration of Conformity . . . . . 186 Emission Control Systems . . . . . 85 Warranty . . . . . . . . . . . . . . . . . . 189 Maintenance . . . . . . . .
Introduction Safety Words and Symbols 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
Introduction WARNING Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner’s manual.
Introduction 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. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Introduction Vehicle Identification Numbers 1 2 Vehicle Model Number: ________________________________________________________________________ Frame Vehicle Identification Number (1): __________________________________________________________ Engine Serial Number (2):______________________________________________________________________ Key Number (on the key): ______________________________________________________________________ 9
Safety Safety Training ATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase price of your ATV.
Safety Safety Training A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Follow the recommended maintenance program outlined in your owner's manual. This program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.
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 Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Long Sleeves 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.
Safety Safe Riding Gear 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 Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Operator Restrictions/Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain. Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.
Safety Safety Warnings Handling Gasoline Exposure to Exhaust 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.
Safety Safety Warnings Failure to Inspect Before Operating Protective Apparel Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.
Safety Safety Warnings Carrying a Passenger Using Alcohol or Drugs Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV. Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating an ATV.
Safety Safety Warnings Operating on Pavement Operating on Public Roads Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.
Safety Safety Warnings Operating at Excessive Speeds Physical Control of the ATV Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience. Removing a hand from the handlebars or feet from the footpegs during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV.
Safety Safety Warnings Turning Improperly Jumps and Stunts Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds. Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts.
Safety Safety Warnings Improper Hill Climbing Operating on Steep Hills Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 72. Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.
Safety Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • 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 78. • Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. • Always check the terrain carefully before descending a hill.
Safety Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 74. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 75.
Safety Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost Keep body 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 downhill: Keep weight uphill. Never apply engine power.
Safety Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. 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. Always use extra caution on rough, slippery or loose terrain.
Safety Safety Warnings Operating in Unfamiliar Terrain Operating Improperly in Reverse Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
Safety Safety Warnings Improper Vehicle Modifications Operating Over Obstacles Improper installation of accessories or modification of the ATV may cause changes in handling, which could cause loss of control or an accident. Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the footpegs: • Travel slowly. • Balance your weight carefully. • Avoid sudden movements. • Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
Safety Safety Warnings Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
Safety Safety Warnings Operating on Frozen Bodies of Water Physical Skills Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice. Never operate the ATV on a frozen body of water. 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.
Safety Safety Warnings Hot Exhaust Systems Unauthorized Use of the ATV Exhaust system components are very hot during and after use of the vehicle. Hot components can cause 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. Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn.
Safety Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. NOTICE: Replacement safety labels are provided by Polaris at no charge.
Safety Safety Labels and Locations 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 Safety Labels and Locations Age 16 Warning Discretionary/Sport ATV 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. WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.
Safety Safety Labels and Locations 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. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 4.0 psi (27.6 kPa) Rear: 4.0 psi (27.6 kPa) • Maximum Weight Capacity 215 lbs.
Features and Controls Main Key Switch Engine Stop Switch Start Button 38
Features and Controls Main Key Switch The main key switch must be in the RUN position to start the engine. See page 66 for starting procedures. Start Button Press the start button to engage the starter. Always release the start button promptly when the engine starts. 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 If indicator lights fail to operate, check connections. See your Polaris dealer for inspection of the capacitor and voltage regulator.
Features and Controls Lights Headlights Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.
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. Adjusting Knob 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. The adjustment range is limited.
Features and Controls 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 172 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2.
Features and Controls Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. 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 The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to increase engine speed and vehicle movement. Fuel is injected into the intake passage each time throttle is applied. Do not squeeze the throttle lever while starting the engine. Do not squeeze the throttle lever when the engine is stopped. Engine speed returns to idle when the lever is released. See page 141 for throttle adjustment procedures.
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.
Features and Controls Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar. These brakes are hydraulically activated disc type brakes. Squeeze the brake lever toward the handlebar to engage the front 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 WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
Features and Controls Master Cylinder/Brake Fluid 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 172 for the part numbers of Polaris products. Hand Brake Fluid Level 1. Position the ATV on a level surface. Position the handlebars so the master cylinder is level. 2. View the fluid level through the indicator window on the side of the master cylinder. 3.
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. WARNING! Operating the ATV while the parking brake is engaged could result in an accident.
Features and Controls Parking Brake 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. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
Features and Controls 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. See page 53. To downshift, place your foot on the gear shift pedal and depress the pedal one full stroke.
Features and Controls Manual Shift Shifting Gears 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. Do not apply throttle. 3. Squeeze the clutch lever to disengage the clutch. 4. Depress the gear shift pedal one full stroke to shift into first gear. 5. Release the brake lever. 6. Gradually squeeze the throttle lever while slowly releasing the clutch lever. 7.
Features and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally. The switch must be manually unlocked before shifting into reverse gear. The lock will automatically re-engage when the transmission is shifted out of reverse gear. 1. Place the transmission in first gear. See page 52. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3. Shift down into 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 speed decreases, disengage the clutch and shift to a lower gear. Be sure engine speed has sufficiently decreased before downshifting. WARNING! Improper use of the brakes or shifting when the engine speed is too high can cause the tires to lose traction or stop rotating, which could result in loss of control.
Features and Controls Choke 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 66 for correct choke and throttle settings during starting. Choke Knob 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 fuel with ethanol content greater than 10 percent, such as E-85 fuel.
Features and Controls Fuel Valve The fuel valve is located on the right side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. Turn the fuel valve off whenever the vehicle is stored or parked. ON: For normal operation. RES: For reserve supply if main supply is exhausted. 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.
Operation WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period 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.
Operation Break-In Period Perform the following break-in and maintenance procedures carefully. 1. Fill the fuel tank with gasoline. Always 5. Excessive heat build-up during the first exercise extreme caution whenever hanthree hours of operation will damage dling gasoline. close-fitted engine parts. Do not allow engine speed to exceed 7000 RPM dur2. Check the oil level. Add the recoming the first three hours of use. mended oil as needed to maintain the oil level in the proper range. See page 99. 6.
Operation Pre-Ride Inspection Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
Operation Pre-Ride Inspection Pre-Ride Checklist Page Coolant (if applicable) Ensure proper level Coolant hoses (if applicable) Inspect for leaks 109 Throttle Ensure smooth operation Indicator lights / switches Ensure operation Engine stop switch Ensure proper operation 39 Air filter Inspect, clean, replace as needed 112 -44 40, 41 Air box sediment tubes Drain deposits when visible Headlamp Verify operation, apply Polaris dielectric grease to the socket when the lamp is replaced -- Br
Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 10. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Never carry a passenger on this ATV. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Operate this vehicle off-road only.
Operation Safe Operation Practices 8. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footpegs. 9. Never consume alcohol or drugs before or while operating an ATV. 10. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure. 11. Never operate a damaged ATV.
Operation Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
Operation Trail Etiquette Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.
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. 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. NOTICE: Operating the ATV immediately after starting could cause engine damage.
Operation Starting the Engine 5. Move the engine stop switch to the RUN position. Turn the ignition key to ON. 6. 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 52. 7. Do not apply throttle. Press the start button to start the engine.
Operation Driving Procedures 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. See page 52. 5. Check your surroundings and determine your path of travel. 6. Release the parking brake. 7. Slowly depress the throttle with your right thumb while slowly releasing the clutch lever to begin driving. 8. Drive slowly.
Operation Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turning, and the inside tire slips traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg.
Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.
Operation Driving on Slippery Surfaces 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3. Always check the terrain carefully before ascending any hill. 4. Never climb hills with excessively slippery or loose surfaces.
Operation Driving Uphill 5. Keep both feet on the footpegs. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards. 8. Never back down a hill. WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover. 9. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 10.
Operation Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill 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.
Operation Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around: 1. Keep your body weight uphill. 2. Pull in the clutch lever and apply the front and rear brakes. 3. When completely stopped, shut off the engine. Leaving the transmission in gear, release the clutch lever and lock the parking brake. 4. Dismount on the uphill side of the vehicle, or on the left side if the vehicle is pointing straight uphill. 5.
Operation Turning Around on a Hill 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. With the front brakes still applied, release the clutch lever and lock the parking brake. Remount from the uphill side, keeping body weight uphill. 76 8 ft. (2.
Operation Turning Around on a Hill 9. Pull in the clutch lever, shift into neutral and restart the engine. 10. Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Stay in first gear, using the brakes for additional speed control if necessary, until more level ground is reached. 11. Follow proper procedures for driving downhill. See page 78.
Operation Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Shift to the lowest gear possible while maintaining a safe speed. 6. Do not apply the brakes abruptly when driving downhill. Apply the foot brake slightly to aid in slowing.
Operation Parking on a Hill or Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 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 Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. 3. Avoid operating through deep or fast-flowing water.
Operation Driving Through Water NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footpeg level. As soon as possible, perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 87. Engine oil and all grease fittings need special attention.
Operation Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly while backing.
Operation Driving in Reverse 7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed. 8. Always look left, right and behind the ATV before backing. NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.
Operation Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
Emission Control Systems Noise Emission Control System 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 USFS standard 5100-1c.
Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
Maintenance Periodic Maintenance Chart Routine inspection and service are critical to the performance and reliability of your high performance engine. Failure to perform the recommended maintenance procedures outlined in the Periodic Maintenance Chart will result in forfeited warranty coverage as well as decreased performance and reliability of the vehicle. If you're unable to perform the required service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance Periodic Maintenance Chart The recommended service intervals are based on average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.
Maintenance Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always 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.
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 90 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 Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Outer clutch cover Maintenance Interval (whichever comes first) Hours Calendar ------ Pre-ride 3 Break-in Remarks Fuel Used See Page in gallons (liters) ------ 5 (20) Check each day before operating the vehicle. Make adjustments as needed.
Maintenance Periodic Maintenance Chart Item XE X X E E 92 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 Shift lever bolt Valve clearance Clutches Spark plug 15 15 15 15 15 30 30 6M 6M 6M 6M 6M 6M 6M 26 (100) 26 (100) 26 (100) 26 (100) 26 (100) 52 (200) 52 (200) Remarks Fuel Used See Page in gallons (liters) Inspect re
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 axle/eccentric (3) 45 30 6M 3M --- 1 Remarks Inspect; tighten fasteners; grease after washing ATV/driving in water Inspect; tighten fasteners; grease (also after washing ATV or driving in water) 2 2 3 94
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 ra
Maintenance Periodic Maintenance Chart Item E E E E E E E E 96 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 (60
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 entire
Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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. Do not use Polaris PS-4 Performance Synthetic 10W-40 Oil. Always use 2W-50. See page 172 for the part numbers of Polaris products.
Maintenance 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 between the 1/2 and 3/4 levels in 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 Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. Change the oil more frequently on vehicles subjected to severe use. IMPORTANT: Perform the initial break-in oil change after the first three hours of operation. Always change both oil filters and clean the oil screens whenever changing oil. Before beginning the oil change procedure, read through the entire procedure. Be prepared to complete the procedure entirely.
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 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. (20 Nm).
Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Oil Screen Plug Front Short Screen View from bottom of vehicle 102 O-Rings
Maintenance Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine. 2. Remove the short oil screen. Clean the screen components thoroughly and blow well with low pressure compressed air. 3. Check the O-rings. If damaged, install new O-rings. 4. Reinstall the screen to the plug. 5. Lubricate the threads and reinstall the plug. Torque to 7.5 ft. lbs. (10 Nm).
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 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. NOTICE: 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. 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 98). 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.
Maintenance Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. If the fluid level is visible at the bottom of the side panel, add 6 oz. (175 ml) of coolant. 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 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. Pressure Cap CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 1. Remove the pressure cap. 2.
Maintenance Engine Cooling System 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. 2. 3. 4. 5. 6. 7. 8. 9. 112 Remove the seat. Release the airbox cover clips and remove the cover. Remove the wing nuts securing the filter to the airbox. Pull the filter assembly out of the air box. Note the placement of the rubber ring for reinstallation. Wash the filter in soapy water, then rinse and let dry. Apply a commercially available foam filter lubricant to the foam filter.
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 17001800 RPM will result in easier starting. If idle speed is unsatisfactory, make adjustments as outlined on page 113. Idle Speed 1. Position the vehicle on a level surface. 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 87. 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 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. 25 ft. (7.
Maintenance Lights Headlight Adjustment 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. Include rider weight on the seat when measuring. 5. Loosen the pivot screw and adjust the beam to the desired position. 6. Tighten the screw and torque to 27 in. lbs. (3 Nm).
Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. 1. Remove the wire harness connector from the back of the headlight. 2. Grasp the bulb housing and turn it counterclockwise to remove the bulb. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 3.
Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover. 2. Remove the wire harness connector from the headlight. 3. Remove the two retaining brackets and the adjuster screw. 4. Remove the headlamp. 5. Install the new headlamp, placing it in the slots on the frame tabs. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it loose so the headlight can be adjusted. 7. Connect the wire harness to the headlamp. Reinstall the front cover. 8.
Maintenance Front Cab/Side Panel Removal The front cab and side panel assembly is removed in one piece. 1. Remove the seat. 2. Remove the two front cover screws and remove the front cover. 3. Remove the eight side panel screws (four on each side). 4. Remove the fuel cap. 5. Gently pull the side panel/cab assembly upward and rearward. 6. Unplug the key switch and the indicator panel before removing the cab. 7.
Maintenance Rear Cab Removal 1. Remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts and grommets (2) on the top of the cab. 4. Remove the two bolts (3) at the rear cab-to-front-cab joint. 5. Unplug the taillight connector. 6. Remove the cab.
Maintenance Spark Plugs Refer to the specifications section beginning on page 168 for recommended spark plug type and gap. NOTICE: Using non-recommended spark plugs can result in serious engine damage. 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. Immediately check the spark plug for correct color. 1.
Maintenance Spark Plugs 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. 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. A damp oil film covers the firing end.
Maintenance Spark Arrestor Clean-Out WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.
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 87. 1. Remove the retaining screw and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 3. Inspect the screen for wear and damage. Replace a worn or damaged screen. 4.
Maintenance Vehicle Immersion If the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stops during or after operating in water, restarting WILL result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined below. This procedure will allow short-term operation only to drive the ATV to a trailer or towing vehicle.
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 112. Drain the carburetor bowl. See page 114. Remove the spark plug. See page 122. WARNING! Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts. Wear protective eyewear and 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 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 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.
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. 130 Remove the rear cab (see page 120). Disconnect the hold-down strap securing the battery in position. Disconnect the black (negative) battery cable first.
Maintenance Battery Installation 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. Place the battery in the battery holder. 2. Connect and tighten the red (positive) cable first. 3. Connect and tighten the black (negative) cable last. 4. Attach the hold-down strap. 5. Reinstall the rear cab. 6.
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. 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) The Polaris Battery Tender battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre-determined point. If the battery fails to recharge during vehicle operation, check voltage regulator connections. See your Polaris dealer for inspection of the voltage regulator and generator.
Maintenance Battery Charging (Sealed Battery) 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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Always ensure that all nuts are torqued to specification.
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. 136 Stop the engine. Place the transmission in gear.
Maintenance Wheel Installation 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. Never install the rim with the valve stem to the inside of the vehicle. 3. Install the wheel bolts and finger tighten them. 4. Lower the vehicle to the ground. 5. Securely tighten the bolts to specification. See page 136.
Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system. See page 43. 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.
Maintenance Clutch System Bleeding 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. 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 141. 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. Locking Nut Sleeve 2.
Maintenance Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. 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.
Maintenance Brakes 1. Always maintain brake fluid at the recommended level. See pages 48-49. 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. Pads should be changed when worn to 3/64" (1 mm).
Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting. 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. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position.
Maintenance Toe Alignment 3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straightedge instead of string. 4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be between 0" and 1/16" (0-1.5 mm) more than the front measurement. 5. Repeat the measurement procedure on the other side of the vehicle.
Maintenance Chain Tension Inspection Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. NOTICE: Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in the illustration so that the axle, swing arm pivot and drive sprocket are aligned horizontally (2).
Maintenance Chain Tension Inspection 1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fasten the strap around the axle and rear bumper tube. 2. Tighten the strap until a straight line (2) can be drawn from the axle to the transmission output shaft, intersecting the swing arm pivot. This establishes the tightest chain position. 3. At the center point of the chain (3) deflection should be 1/4" - 3/8" (6-9 mm).
Maintenance Chain Tension Adjustment 1. 2. 3. 4. 148 Loosen the two eccentric locking bolts. Refer to the illustration on the following page. Insert a pin punch into the eccentric axle housing. Roll the vehicle slightly to adjust chain slack to the proper dimension. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm).
Maintenance Chain Tension Adjustment Step 2 Step 1 Proper splicelink clip opening position 149
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. 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.
Maintenance Steering Inspection 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 Suspension Settings Use a flat-blade screwdriver to make damping adjustments. When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.
Maintenance Front Suspension Compression Damping (Limited Edition) To adjust the front suspension compression damping, use the adjustment procedures outlined for the rear suspension compression damping on page 157. Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. See page 154.
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. Loosen the jam nut and back it away from the adjusting ring. 3. Turn the adjusting ring to the left (1) to increase preload for a stiffer ride. Turn the adjusting ring to the right (2) to decrease preload for a softer ride. See Suspension Settings on page 152.
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. Loosen the jam nut and back it away from the adjusting ring. 3. Turn the adjusting ring to the left (1) to increase preload. Turn the ring to the right (2) to decrease preload.
Maintenance Rear Suspension Rebound Damping Use a flat-blade screwdriver to make damping adjustments. The rebound damping is factory set at 16 clicks from fully closed. See Suspension Settings on page 152. 1. Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount. 2. Turn the clicker counter-clockwise (1) to decrease the rebound damping. Turn the clicker clockwise (2) to increase rebound damping.
Maintenance Rear Suspension Compression Damping Use a flat-blade screwdriver to make damping adjustments. The factory setting is at 10 clicks from fully closed. See Suspension Settings on page 152. The compression damping clicker is located on top of the shock reservoir, under the right rear fender. 1. Turn the clicker clockwise (1) to increase compression damping. 2. Turn the clicker counter-clockwise (2) to decrease compression damping.
Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: 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 Washing Tips • • • • Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. 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 Cleaning 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. 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 NOTICE: 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 158. Battery Storage Refer to pages 129-134 for battery storage and battery charging procedures.
Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 100. 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 87.
Maintenance Storage 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. 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 87. 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. Do not use plastic or coated materials.
Maintenance Transporting the ATV 1. 2. 3. 4. 5. 6. 7. 166 Stop the engine. Place the transmission in first gear. Lock the parking brake. Remove the key to prevent loss during transporting. Secure the fuel cap, oil cap and seat. Turn the fuel valve off. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.
Maintenance Transporting the ATV 167
Specifications OUTLAW 450 MXR Max. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity 215 lbs./98 kg 360 lbs./163 kg 3.1 gal./11.8 l 71.5 in./182 cm 47 in./119 cm 45 in./114 cm 50.5 in./128 cm 5 in./13 cm 67 in./170 cm 1.7 qts./1.
Specifications OUTLAW 450 MXR 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 Headlight Taillight Brakelight 20 x 6R10 18 x 10R9 4 psi/27.
Specifications OUTLAW 525 S Max. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity 215 lbs./98 kg 370 lbs./168 kg 3.1 gal./11.8 l 71.5 in./182 cm 47.5 in./121 cm 45 in./114 cm 50.5 in./128 cm 5 in./13 cm 67 in./170 cm 1.7 qts./1.
Specifications OUTLAW 525 S 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 Taillight Brakelight 21 x 7R10 20 x 11R9 4 psi/27.
Polaris Products Part Number 2876244 2876245 2871312 2871322 2871423 2871460 2871329 2872073 2872348 1350046 172 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 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.
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 177
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 179
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 181
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 Check oil level, maintain at recommended level See your Polaris d
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 radiator 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 185
Declaration of Conformity Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles.
Declaration of Conformity PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___KA05__ ___KA09__ ___FA09__ ___VA17__ ___PB20__ ___BA32__ ___CA32__ ___BA50__ ___GJ45__ ___GJ52__, ___GP52__ ___LH27__ ___LH46__ ___MN50__ ___ZN55__ ___ZX55__ ___TN55__, ___DN55__ OUTLAW 50 OUTLAW 90 SPORTSMAN 90 RZR 170 PHOENIX 200 TRAIL BLAZER 330 TRAIL BOSS 330 SCRAMBLER 500 OUTLAW 450 OUTLAW 525 SPORTSMAN 300 SPORTSMAN 400 SPORTSMAN 500 EFI SPORTSMAN 550 EFI SPORTSMAN X2/TOURING 550 2008,
Declaration of Conformity VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___MN76__ ___TN85__, ___DN85__ ___CL76__ ___ZN85__, ___ZX85__ ___RH50__, ___HH50__ ___HH76__ ___WH76__ ___HR__ ___HY__ ___VH76__ SPORTSMAN 800 SPORTSMAN X2/TOURING 850 SPORTSMAN 800 6X6 SPORTSMAN 850 EFI RANGER 500 EFI 4X4 RANGER 800 EFI 4X4 RANGER 800 EFI CREW RANGER 800 6X6 RANGER HD 800 4X4 RANGER RZR 2008, 2009, 2010 2010 2009, 2010 2009, 2010 2009, 2010 2010 2010 2010 2010 2008, 2009, 2010 83.6 77.2 80.1 80.
LIMITED WARRANTY 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 COVERAGE AND EXCLUSIONS: Warranty LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair.
Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of af
WARRANTY COVERAGE AND EXCLUSIONS: Warranty 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.
EXPORTED VEHICLES Warranty 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 If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage.
U.S.A. EPA Emissions Limited Warranty Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
Warranty U.S.A.
U.S.A. EPA Emissions Limited Warranty 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.
Warranty U.S.A. EPA Emissions Limited Warranty This limited warranty excludes failures not caused by a defect in material or workmanship.This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing competition.
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 90 202 TECHNICIAN SERVICE PERFORMED / COMMENTS
Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 203
Maintenance Log DATE 204 SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS
Index A Age Restrictions . . . . . . . . . . . . . . 15 Air Filter Systems . . . . . . . . . . . . 112 B Battery Charging. . . . . . . . . . . . 132-134 Installation . . . . . . . . . . . . . 131 Maintenance. . . . . . . . . . . . 129 Removal . . . . . . . . . . . . . . . 130 Storage . . . . . . . . . . . . 130, 162 Bleeding the Cooling System . . . 111 Boots . . . . . . . . . . . . . . . . . . . . . . . 14 Brake Fluid . . . . . . . . . . . . . . . . 48-49 Brake Maintenance . . . . . . . .
Index F Fluid Brake . . . . . . . . . . . . . . . . 48-49 Clutch . . . . . . . . . . . . . . . . . . 43 Foot Brake . . . . . . . . . . . . . . . . . . . 46 Foot Brake Fluid Level . . . . . . . . . 49 Fuel Filter . . . . . . . . . . . . . . . . . . . . 56 Fuel Safety . . . . . . . . . . . . . . . . . . . 17 Fuel Stabilizer . . . . . . . . . . . . . . . 164 Fuel Tank . . . . . . . . . . . . . . . . . . . . 56 Fuel Valve . . . . . . . . . . . . . . . . . . . 57 G Gasoline Handling . . . . . . . . . . . . .
Index R Rebound Damping, Rear. . . . . . . 156 Restrictions, Age. . . . . . . . . . . . . . 15 Reverse Lock-Out Switch . . . . . . . 54 Riding Area. . . . . . . . . . . . . . . . . . 64 Riding Gear. . . . . . . . . . . . . . . . 13-14 S Safe Operation Practices . . . . . . 62-63 Safety Labels and Locations . 34-37 Age 16 Warning. . . . . . . . . . 36 Discretionary Warning. . . . . 36 General Warning . . . . . . . . . 35 No Passenger Warning. . . . . 37 Sport ATV Warning. . . . . . .
Index S Spark Arrestor Clean-Out. . . 124-125 Spark Plugs. . . . . . . . . . . . . . 122-123 Spring Preload . . . . . . . . . . . . . . . 153 Spring Preload, Front . . . . . . . . . . 154 Spring Preload, Rear . . . . . . . . . . 155 Starting the Engine . . . . . . . . . . 66-67 Steering Inspection . . . . . . . . . . . . 151 Storage . . . . . . . . . . . . . . . . . 162-165 Suspension Front . . . . . . . . . . . . . . 153-154 Rear . . . . . . . . . . . . . . . 155-157 Suspension Settings . . . . . . . . .
