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.
Pantone 426C WARNING NEVER operate: S without proper training or instruction S at speeds too fast for your skills or the conditions S on public roads - a collision can occur with another vehicle S with a passenger - passengers affect balance and steering and increase risk of losing control Improper vehicle 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 READ OWNER'S MANUAL.
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POLARIS and POLARIS THE WAY OUT 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 Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you. We've provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV. A Polaris ATV is not a toy and can be hazardous to operate. Make sure any child who will operate the ATV takes a training course before operating the ATV.
Welcome Dear Children: Before you ride your new Polaris ATV, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner's manual. You must also take an ATV training course before you begin riding.
Table of Contents Introduction. . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . 8 Youth Section . . . . . . . . . . . . . . 39 Know Your ATV . . . . . . . . . . . 40 Pre-Ride Check . . . . . . . . . . . 47 Riding Rules . . . . . . . . . . . . . 50 Adult Section. . . . . . . . . . . . . . . 55 Vehicle ID Numbers. . . . . . . . 56 Features and Controls . . . . . . 57 Operation. . . . . . . . . . . . . . . . 70 Emission Control Systems. . . 92 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.
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 If you purchased a used Polaris ATV in the United States, you can enroll in the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org. If you purchased a Polaris ATV outside the United States, please contact your dealer or local law enforcement agencies for information about safety training. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.
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 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. Approved helmets in Europe, Asia and Oceania bear the ECE 22.
Safety 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 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 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. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child's safety. Be sure to explain to your young driver that the hazards outlined in this section of the owner’s manual MUST be avoided at all times.
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 an ATV training course. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual. See page 8.
Safety Safety Warnings Handling Gasoline Exposure to Exhaust Gasoline is highly flammable and explosive under certain conditions. • Never allow a child to refuel or handle gasoline. • 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 footrests 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 82. 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 15 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 85. • Always check the terrain carefully before descending a hill. • Shift your weight rearward. • Never travel down a hill at high speed.
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 84. 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 86.
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 If you lose all forward speed: Keep your weight uphill. Apply the front brakes gradually (right lever). When fully stopped, apply the rear brake as well (left lever) and then lock the parking brake. If the ATV begins rolling downhill: Keep weight uphill.
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 Improper Tire Maintenance 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 footrests: • 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 Improper Cargo Loading Overloading the ATV or carrying/towing cargo may cause changes in handling, which could cause loss of control or an accident. Never haul cargo or tow a load with this ATV. Never tow or pull an object behind the ATV. A wagon, sled or other towed object does not have brakes or steering. The object may overturn or collide with other objects. Never exceed the stated load capacity for this ATV.
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. Always inspect the underside of the ATV after driving through tall grass, weeds, brush and other tall ground cover.
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. Replacement safety labels are provided by Polaris at no charge.
Safety Safety Labels and Locations Operation 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 Warning WARNING Operation of this ATV by children under the age of 6 increases the risk of severe injury or death. Adult supervision required for children under age 16. NEVER permit children under age 6 to operate this ATV.
Safety Safety Labels and Locations Tire Pressure Warning 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: 2.0 psi (13.8 kPa) Rear: 2.0 psi (13.8 kPa) • Maximum Weight Capacity 90 lbs.
Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
Safety Safety Labels and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not touch clutch cover, cover may become hot. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
38
Youth Section 39
Know Your ATV PARENTS: Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experience. More information on speed limiting functions can be found beginning on page 122. These units are not designed for adult use. Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section beginning on page 156 for your ATV's capacity.
Know Your ATV Before you have an adult start the engine for you for the first time, let's learn about the controls on your new ATV. 1. Engine Stop Switch - When the engine is running, push this button down to shut the engine off quickly. The button must be up before you can start the engine again. 2. Horn Button - Press the horn button to sound the horn. 3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to go forward.
Know Your ATV 4. Kick-Start Lever - If your battery is too weak to start your ATV, you can push down on the kick-start lever with your foot to start the engine. Have an adult show you how it works. Read more about how to use the kick-start on page 68. 4.
Know Your ATV 5. Gas Cap - The gas cap has to be taken off when an adult puts gas in your ATV. Never take the gas cap off. Always make sure it's tightly closed. 5. Gas Cap 6. Seat Latch Always have an adult put gas in your ATV. Never try to do it yourself. 6. Seat Latch - The seat latch is under the left edge of the seat. Reach under the left rear fender and pull back on the latch to remove the seat. To replace the seat, set it in place and push down on the seat above the latch.
Know Your ATV 7. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured. Always take your thumb off the throttle lever when you squeeze the brake levers. 7. Rear Brakes 44 7.
Know Your ATV 8. Ignition Switch - The ignition switch key must be turned on before pushing the start button. You can also use this key to turn off the engine. 9. Tether Strap and Switch - The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive. If you fall off your ATV, the tether strap will pull away from the switch and the engine will stop. 8. Ignition Switch 9.
Know Your ATV Let's review the three ways to stop the engine of your ATV: 1. Push the engine stop switch down. 2. Pull the tether strap off the ATV. 3. Turn the key off.
Pre-Ride Check We're almost ready to have an adult start your ATV. But before the ATV is started for the first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check some things on your ATV before starting it. Let's learn about these things now. n Make sure the throttle doesn't stick. Check this by pushing the throttle lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it.
Pre-Ride Check n Make sure the brakes don't stick. Check the brake levers by squeezing them toward the handlebar and then letting go. They should come right back to where they were before you squeezed. If they go back slowly or stay close to the handlebar, your ATV has sticky brakes. They must be fixed before you can ride your ATV safely. Never start the engine if your ATV has sticky brakes. You could be seriously hurt if you ride with sticky brakes.
Pre-Ride Check n If you used the storage area under the seat, make sure the seat is locked in place. n Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been running and it can burn your skin if you touch it. Children must never check the oil on their own. An adult should always be in charge of keeping the gas and oil levels at the full marks. n This last check is done with the engine running.
Riding Rules Now you're ready to learn about riding your Polaris ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride. X The adult with you is your teacher. Always pay attention to what your teacher says so you can learn how to always drive safely. Let's learn how to ride! Always follow the safe riding rules found on the next pages.
Riding Rules Always wear the right kind of clothing and safety gear when riding your ATV. Long Helmet Helmet: Your helmet is very important for safe riding. A Sleeves helmet can prevent a severe head injury. Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you can see where you're driving. Eye Protection Gloves Gloves: Wear gloves to protect your hands from sun and wind. Gloves will also protect your hands from scrapes Long Pants and scratches.
Riding Rules Always attach the tether strap to your right wrist and to the ATV before riding. X Make sure you know where you're going to drive before your ATV is started. Make sure the area is safe all around your ATV. X Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder to drive. You may lose control and hurt yourself and your passenger. X Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on the footrests.
Riding Rules Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. X Never ride on public trails. X Don't ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. X Don't ride at night. Your ATV doesn't have lights that are safe for driving in the dark. X Learn where there are lakes, rivers, ponds and ditches in your driving area.
Respect your ATV; respect your environment; and you will earn the respect of everyone.
Adult Section 55
Vehicle Identification Numbers Record your ATV's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. 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.
Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. Always remove the ignition key when the vehicle is not in use.
Features and Controls Engine Stop Switch The engine will not start or run when the stop switch is down, in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle. To stop the engine quickly, push the stop switch down. Horn Start Button Stop Switch Choke Lever Choke Lever Use the choke to start a cold engine.
Features and Controls Horn Button Use the horn for emergencies and to let others know you’re near. Engine Start Button The start button is located slightly above the choke lever. 1. Attach the tether strap securely to the vehicle and to the rider's right wrist. 2. Turn the key to the ON position. 3. Lock the parking brake. 4. Push the engine stop switch up to the ON position. 5. Press the start button.
Features and Controls Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
Features and Controls Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released. 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 and power to the rear wheels will cease.
Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes. WARNING! Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time.
Features and Controls Brakes Parking Brake 1. Squeeze the left brake lever. 2. Push the parking brake lock down to lock the brake lever in place. 3. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. Not Locked Locked WARNING! Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage.
Features and Controls Brakes Parking Brake The CVT system is always in forward gear. Using the throttle to warm the engine will cause the vehicle to move forward if the parking brake is not locked. Always lock the parking brake before starting the engine. Always lock the parking brake whenever the vehicle is left unattended. Lights WARNING Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark.
Features and Controls Fuel System Gas Cap Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel. Refer to the specifications section beginning on page 156 for fuel tank capacity.
Features and Controls Fuel Valve The fuel valve is located on the left side of the ATV. It has three settings. OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. The reserve setting allows operation for approximately 7-10 miles (11-16 km). Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.
Features and Controls Footwell Riser The removable footwell risers improve riding ergonomics and provide comfort for shorter operators. An operator will also have better control of the ATV when both feet can remain firmly planted on either the footwells or the risers. If the operator's legs are long enough to comfortably reach the footwells without the risers, the risers can be removed. 1. Remove the rubber caps covering the screw access holes. Cap 2.
Features and Controls Kick-Start Lever If the battery becomes too weak to start the Kick-Start Lever engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3. Fold out the kick-start lever on the left side of the vehicle. 4. Push the engine stop switch up to the ON position. 5. Turn the key to ON. 6. Place your foot on the kick-start, then thrust your heel downward to crank the engine. 7.
Features and Controls Kick-Start Lever 8. If the kick-start lever is not installed, remove the lever from the under-seat storage area. 9. Remove the plug from the kick-start access hole on the left side of the vehicle. Tip: Store the plug in a secure location. Always reinstall the access hole plug whenever the kick-start lever is removed from the vehicle. 10. Install the kick-start lever through the access hole.
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 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
Operation Break-in Period 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. See page 15. 2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the proper range. See page 105. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with operation and handling. Item 4. Vary throttle positions. Do not operate at sustained idle. 5.
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 Item Remarks Throttle Check for proper operation Engine stop switch Check for proper function Page 47, 60, 61 58 Daytime running lights (if equipped) Check for proper operation 143 Brakelight Check for proper operation 142 Air filter, pre-filter Inspect, clean or replace 136 Drive chain Check condition and slack; refer to drive chain adjustment 133 Frame nuts, bolts, fasteners Inspect, ensure tightness -- Loose or damaged components Vis
Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 8. 2. Do not allow anyone under 6 years of age 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. 74 5. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads. 6.
Operation Safe Operation Practices 7. 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 footrests. 8. Never consume alcohol or drugs before or while operating an ATV. 9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure. 10. Never operate a damaged ATV.
Operation Starting the Engine NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. 2. 3. 4. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle. Attach the tether strap to the ATV and to your wrist. 5. If the engine is cold, use full choke by pushing the choke lever all the way to the left. Do not use the choke when starting a warm engine.
Operation Starting the Engine 6. Push the engine stop switch up to the ON position. 7. Turn the ignition key to ON. 8. Squeeze the rear brake lever and press the start button. The rear brake lever must be engaged for the engine to start. 9. Do not press the throttle while starting the engine. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn't start, release the starter, wait five seconds, then activate for another five seconds.
Operation Stopping the Engine 1. Release the throttle completely. 2. Apply the brakes until the vehicle stops moving. 3. Stop the engine. There are three ways to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. 4. Lock the parking brake. 5. To avoid draining the battery, always turn the key to the OFF position when the engine is not running.
Operation Driving Procedure 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Lock the parking brake. 4. Start the engine and allow it to warm up. 5. Check your surroundings and determine your path of travel. 6. Slowly squeeze and release the left brake lever to unlock the parking brake. 7. Slowly press the throttle with your right thumb and begin driving. 8. Drive slowly at first.
Operation Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.
Operation Driving 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.
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 (15° 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 footrests. 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 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. 9. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
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 footrests. 3.
Operation Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (15° 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. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing.
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. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2. Shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
Operation Turning Around on a Hill 4. Staying uphill of the ATV, turn the handlebars full left. 5. While holding the brake, release the parking brake lock and slowly release the brake, allowing the ATV to roll around to your right until it's pointing across the hill or slightly downward. 6. Lock the parking brake and remount the ATV from the uphill side, keeping body weight uphill. 7. Restart the engine. 8. Squeeze the rear brake lever. 9.
Operation Parking on a Hill or Incline Avoid parking on a hill or incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Lock the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illustration. 4. Turn the fuel valve off.
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. 4. Never apply the brakes during a skid.
Operation Driving Through Water Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. If crossing a stream, choose a crossing where both banks have gradual inclines. 3. Avoid operating through deep or fast-flowing water.
Operation Driving Through Water 4. After driving through water, dry the brakes by applying light pressure to the levers (while moving) until braking action is normal. If you do not perform this procedure, your brakes may be ineffective. NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footrest level. As soon as possible, perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 94.
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 To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Record maintenance and service in the Maintenance Log beginning on page 181.
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. 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 cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often under severe use, such as in dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Q E Calendar Remarks Miles (Km) Steering -- Daily -- Front suspension -- Daily -- Rear suspension -- Daily -- Tires -- Daily -- Brake lever travel -- Daily -- Brake system -- Daily -- Wheels/fasteners -- Daily -- Frame fasteners -- Daily -- Engine oil level -- Daily -- Air filter, pre-filter & main element -- Daily -- Air box sediment tube -- Daily -- Drain deposi
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) Drive chain -- Daily -- Inspect daily; adjust and lubricate if needed 133 CVT housing (if equipped) -- Weekly -- Drain water as needed, check often if operating in wet conditions 117 Perform break-in maintenance 70 XQ Brake lever travel/brake freeplay Break-in Maintenance 10 Monthly 100 (160) Inspect regularly 125 129 E Spark plug 10 Monthly 100
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Remarks Miles (Km) See Page Battery 20 Monthly 200 (320) Check terminals; clean; test 144 X Engine oil change 30 6M 300 (480) Drain and change the oil 106 X Transmission oil 40 12 M 400 (640) Drain and change the oil 110 X Oil pre-filter screen 40 12 M 400 (640) Clean filter at every oil change; clean annually if ATV is operated less than 10 hours 107 X General lubricatio
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) 50 6M 500 (800) Check for proper sealing/air leaks -- E Carburetor air intake ducts/flange Q Drive belt 50 6M 500 (800) See your Polaris dealer -- XQ Brake pad wear 50 6M 500 (800) See your Polaris dealer -- QE Fuel system 100 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks See Page X Wiring 100 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
Maintenance Lubrication Guide Item Lube Method Engine Oil Polaris Synthetic Youth Oil or Synthetic SAE 40 See page 104. Gearcase (Transmission) Oil Level Premium AGL Synthetic Gearcase Lube See page 110. Drive Chain Polaris Chain Lube or SAE 80/ 90 See page 133. X Front Suspension Polaris All Season Premium Grease or grease conforming to NLGI No. 2 Inspect; tighten fasteners; grease (also after washing ATV or driving in water).
Maintenance Lubrication Guide Grease Points Grease Points 103
Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 94. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 158 for the part numbers of Polaris products.
Maintenance Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4. Remove the dipstick and check the oil level. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
Maintenance Engine Oil Change 1. 2. 3. 4. Position the vehicle on a level surface. Clean the area around the pre-filter plug. Start the engine. Allow it to idle for two to three minutes. Stop the engine. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
Maintenance Engine Oil Change 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry. 8. Clean the pre-filter plug. Install a new sealing washer on the plug. The sealing surfaces on the plug and crankcase should be clean and free of burrs, nicks or scratches. 9. Reassemble the pre-filter screen and spring to the pre-filter plug.
Maintenance Engine Oil Change 10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm). 11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. See the specifications section beginning on page 156 for capacities. 12. Reinstall the dipstick. 13. Start the engine. Allow it to idle for one to two minutes. 14. Stop the engine and inspect for leaks. 15. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick. 16.
Maintenance Fuel Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 94. Do not attempt to clean the fuel filter.
Maintenance Transmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of the ATV. Maintain the oil level at the bottom of the fill plug hole threads. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 94. Polaris recommends the use of AGL Synthetic Gearcase Lubricant. See page 158 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2. Remove the fill plug. 3.
Maintenance Transmission Oil Change 1. 2. 3. 4. 5. 6. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). Add the recommended oil. Maintain the oil level at the bottom of the fill plug hole threads. 7. Reinstall the fill plug. Check for leaks. 8. Dispose of used oil properly. Gearcase Capacity Outlaw 50 11.8 oz.
Maintenance Spark Plugs Refer to the specifications section beginning on page 156 for spark plug and gap specifications. 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.
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 Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service, or after 25 hours. Vehicle Immersion If the vehicle tips or overturns in water deeper than the footrest 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.
Maintenance Vehicle Immersion 5. Loosen the carburetor drain screw. 6. Turn the engine over several times using the electric start. 7. Dry the spark plug and reinstall it, or replace it with a new plug. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 12.
Maintenance Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
Maintenance Constant Variable Transmission (CVT) System CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cover. 1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and airdry the belt and clutches.
Maintenance Spark Arrestor To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 94. WARNING Failure to heed these warnings could result in serious injury or death. • Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. • Wear eye protection and gloves. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
Maintenance Spark Arrestor 1. Remove the three bolts 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 the arrestor if damage is found. 4. Reinstall the arrestor. 5. Torque the bolts to 7 ft. lbs. (9.5 Nm).
Maintenance Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
Maintenance Carburetor If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine. 2. Lock the parking brake. 3. Allow the engine to run for approximately five minutes. 4. Adjust the carburetor idle screw either in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.
Maintenance Speed Control System Per ANSI / SVIA-1-2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed of youth models is restricted to under 10 MPH for the 50cc models and under 15 MPH for the 90cc models. The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer's request, remove or adjust any speed limiting devices. Your Polaris ATV has an adjustable throttle limiting screw.
Maintenance Speed Control System Throttle Stop Speed Control System Use the following procedure to control how far the throttle opens. 1. Loosen the jam nut. 2. Turn the screw inward to reduce speed or outward to increase speed. 3. Tighten the jam nut after adjusting.
Maintenance Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept between 1/16" and 1/8" (1.5 - 3.2 mm). If adjustment is required, turn the adjustment nut until the freeplay falls in to the acceptable limit. Adjustment Nut 1/16" - 1/8" (1.5 - 3.
Maintenance Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals recommended in the Periodic Maintenance Chart beginning on page 94. If the freeplay isn’t at specification, adjust the freeplay as outlined on the following pages. Measure Freeplay Brake Freeplay Specifications Model Front Brake Rear Brake Outlaw 50 .08”-.12" (2-3 mm) .08”-.
Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface. 2. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground. 3. While rotating the left front wheel, tighten the upper front brake adjuster nut on the right-hand control. 4. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn.
Maintenance Brake Freeplay Front Brake Adjustment 5. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 6. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn. 7. Verify that the right-hand brake functions correctly. 8. Verify that brake lever freeplay is at specification. See page 125. 9. Carefully lower the vehicle to the ground.
Maintenance Brake Freeplay Rear Brake Adjustment 1. Position the vehicle on a level surface. 2. Elevate the rear of the vehicle by placing a suitable stand under the frame. The rear tires should be slightly off the ground. 3. While rotating the rear wheels, tighten the rear brake wing nut at the rear brake drum. 4. When you begin to feel a slight drag in wheel rotation, loosen the wing nut one full turn. 5. Verify that the left hand brake functions correctly. 6.
Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 94. When freeplay specifications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine when to service the brakes. Service the brakes when brake lever travel reaches the total lever travel measurement listed in the Measure table below.
Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. 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. 3.
Maintenance Toe Alignment 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 1/16"-1/8" (2-3 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for service.
Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The rear shock absorber springs are adjustable to increase or decrease spring tension. Rotate the adjuster either clockwise or counter-clockwise to make adjustments.
Maintenance Drive Chain Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 94. Lubricate more often under severe use, such as in dirty or wet conditions. See page 158 for the part numbers of Polaris products. NOTICE: Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure.
Maintenance Drive Chain Slack 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. The chain should have 1/4"-1/2" (6-12 mm) deflection. If the chain needs adjustment, use the procedure on page 135.
Maintenance Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. Turn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). Hold the adjuster stud securely while tightening the nut to avoid breaking the stud. 5. Tighten the four rear housing mount bolts to 43 ft. lbs. (60 Nm).
Maintenance Air Filter 1. Remove the seat. See page 43. 2. Release the air box cover clips and remove the cover. 3. Remove the foam air filter. Wash the foam filter in warm soapy water, then rinse and let dry. If the filter is damaged, install a new foam filter. 4. Apply a commercially available foam filter lubricant to the foam filter.
Maintenance Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter and air box cover. Secure the clips. 7. Reinstall the seat. NOTICE: Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear and severe damage to the engine.
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. Remove the pod to access the handlebar bolts. Loosen the four bolts. 2.
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.
Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 1/8" (3 mm) Wheel Removal 1. Stop the engine and lock the parking brake. 2. Loosen the wheel bolts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel bolts and remove the wheel.
Maintenance Wheel Installation 1. Lock the parking brake. 2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 3. Install the wheel bolts and finger tighten them. 4. Lower the vehicle to the ground. 5. Securely tighten the bolts to 22 ft. lbs. (30 Nm). Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized Polaris dealer.
Maintenance Tail Light Lamp Replacement If the brakelight doesn't work, the lamp may need to be replaced. 1. Remove the two screws securing the lens cover. Remove the lens cover. 2. Remove the lamp and replace it with a new recommended lamp. 3. Test the light for proper operation. 4. Reinstall the lens cover.
Maintenance Daytime Running Lights Lamp Replacement If the daytime running lights do not operate, replace the lamps. Polaris recommends that you install replacement lamps obtained from your authorized Polaris dealer. 1. Disconnect the lights from the harness. 2. Remove the rubber cover from the back of the light assembly. 3. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note the position of the lamp positioning tab, then carefully pull the lamp out. 4. Install the new lamp.
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 battery in your Polaris ATV is a sealed battery. The sealing strip cannot be removed. Never add water to this type of battery. Keep the battery terminals and connections free of corrosion.
Maintenance Battery Battery Removal 1. Remove the three bolts securing the battery mounting bracket to the vehicle. 2. Remove the mounting bracket and battery. 3. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. 4. Loosen the two nuts securing the battery plate to the top of the battery. Remove the plate. 5. Lift the battery out of the mounting bracket.
Maintenance Battery 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 fully charged battery in the mounting bracket. Reinstall the battery plate and tighten the two nuts securely to retain the battery in the mounting bracket. 2. Connect and tighten the red (+) cable first.
Maintenance Cleaning Keeping your ATV 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 ATV 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.
Maintenance Cleaning Washing the ATV 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 • Cab and body panels • Radiator • Labels and decals • Electrical components and wiring • Transmission seals • Brakes 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 Exterior Make necessary repairs and clean the vehicle as recommended. See page 147. Battery Storage 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.
Maintenance Storage Stabilize the Fuel Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
Maintenance Storage Engine Oil Change the oil. See page 106. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and 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 94.
Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 94. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground. 3. Be sure the storage area is well ventilated. 4. Cover the vehicle with an appropriate cover. Do not use plastic or coated materials.
Maintenance Transporting the ATV 1. Stop the engine. Place the transmission in gear. Lock the parking brake. 2. Secure the fuel cap, oil cap and seat. Turn the fuel valve off. NOTICE: Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting. 3. Attach the front tie strap to the frame tubes (not to the bumper tubes). 4. Wrap the rear tie strap around the grab bar.
Specifications Outlaw 50 Rider Capacity Maximum Weight Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 156 1 Rider 90 lbs. (41 kg) 49cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 1.2 gallons (4.5 liters) .22 gallons (.85 liters) Electric with kick-start backup Automatic CVT Chain Single control arm with 3" (7.6 cm) of travel Spring over shock with 3" (7.
Specifications Outlaw 50 Front/Rear Brakes Parking Brake Front Tires Rear Tires Dry Weight Length/Width/Height Wheel Base Ground Clearance Brake Light Daytime Running Lights Drum Mechanical Lock 16 x 6.5 - 7 (2 psi/13.8 kPa) 16 x 8 - 7 (2 psi/13.8 kPa) 210 lbs. (95.3 kg) 48" (122 cm) / 31.
Polaris Products Part Number 2876248 2876249 2872175 2872176 2870791 2873602 2872348 158 Description Engine Lubricant Synthetic Youth Oil (qt/.95 l) Synthetic Youth Oil (gal/3.8 l) Semi-Synthetic 20W-40 Oil (qt/.95 l) Semi-Synthetic 20W-40 Oil (gal/3.8 l) Fogging Oil, Aerosol Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt/.
Polaris Products Part Number 2871322 2871423 2871326 Description Grease All Season Premium Grease (3 oz./89 ml) All Season Premium Grease (14 oz.
Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts.
Troubleshooting Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery with .
Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer 162
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with .
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 Clogged fuel filter Replace filter 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 Replace with lower octane fuel Incorrect jetting See your Polaris dealer 164
Troubleshooting Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn the fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition
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 a
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 100 Hours 120 Hours 150 Hours 182 TECHNICIAN SERVICE PERFORMED / COMMENTS
Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 183
Maintenance Log DATE 184 SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS
Index A Accessories . . . . . . . . . . . . . . . . . 154 Age Restrictions . . . . . . . . . . . . . . 13 Air Filter . . . . . . . . . . . . . . . . 136-137 Axle and Wheel Nuts . . . . . . . . . 141 B Battery Installation and Connections 146 Removal. . . . . . . . . . . . . . . . 145 Storage . . . . . . . . . . . . . 146, 151 Boots . . . . . . . . . . . . . . . . . . . . . . . 11 Brake Adjustment, Front. . . . 126-127 Brake Adjustment, Rear . . . . . . . 128 Brake Freeplay . . . . . . . . . . .
Index H Handlebar Adjustment . . . . . . . . . 138 Helmet . . . . . . . . . . . . . . . . . . . . . . 10 Horn . . . . . . . . . . . . . . . . . . . . . . . . 59 Horn Button . . . . . . . . . . . . . . . . . . 41 I Instruction, Operating. . . . . . . . . . . 14 K Key Switch . . . . . . . . . . . . . . . . . . . 57 Kick-Start Lever. . . . . . . . . 42, 68-69 K-Turn . . . . . . . . . . . . . . . . . . . . . . 86 L Lamp Replacement Daytime Running Lights . . . . 143 Tail Light. . . . . . . . . . . . . .
Index S Safety Warnings . . . . . . . . . . . 13-31 Frozen Bodies of Water . . . . . 30 Handling Gasoline . . . . . . . . . 15 Hot Exhaust Systems . . . . . . . 31 Improper Cargo Loading . . . . 29 Improper Hill Climbing . . . . . 21 Improper Tire Maintenance . . 26 Improper Modifications . . . . . 27 Jumps and Stunts . . . . . . . . . . 20 Operating a Damaged ATV . . 30 Operating at Excessive Speeds 19 Operating on Pavement . . . . . 18 Operating on Public Roads . .
Index T Tire Tread Depth . . . . . . . . . . . . . 140 Tires . . . . . . . . . . . . . . . . . . . . . . . 139 Toe Alignment . . . . . . . . . . . 130-131 Transmission . . . . . . . . . . . . 116-117 Transmission Oil . . . . . . . . . 110-111 Transporting the ATV . . . . . . . . . 155 Turning Around on a Hill. . . . . 86-87 188 V Vehicle Identification Numbers . . 56 Vehicle Immersion . . . . . . . 114-115 W Warranty . . . . . . . . . . . . . . . 177-180 Warranty, Emissions . . . . . .
