WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
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WELCOME Thank you for choosing Polaris, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles. We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today.
WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV Pro 500 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.
TABLE OF CONTENTS Vehicle Identification Numbers . . . . . . . . . . . . . . 6 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . 7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Understanding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 9 Key Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Decals and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operator Safety . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Maintenance and Lubrication . . . . . . . . . . . . . . . 82 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . 82 Lubrication Recommendations . . . . . . . . . . . . . . . . . . . 88 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Filter Systems . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN) (1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to its recovery and identification. NOTE: Record your vehicle’s ID numbers in the spaces provided. Remove the spare key and store it in a safe place.
VEHICLE SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight 1240 lbs. Fuel Capacity 4.75 U.S. Gallons Towing Capacity 1500 lbs Hitch Tongue Capacity 150 lbs Overall Length 85” Overall Width 46” Overall Height 47” Wheelbase 50.75 Ground Clearance 11” Dry Weight 740 lbs Minimum Turning Radius 71.5” Engine Oil Capacity 2 Quarts Coolant Capacity 3.
VEHICLE SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.
SAFETY Understanding Warnings The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Key Safety Issues Protect Your Sport Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others. We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.
SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
SAFETY Key Safety Issues 12 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
SAFETY Key Safety Issues Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse. Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV.
SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
SAFETY Safety Decals and Locations WARNING 1 IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT.
SAFETY Safety Decals and Locations 3 2 16
SAFETY Safety Decals and Locations 2 WARNING UNDER 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. 7078253 3 WARNING Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. 25° REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.
SAFETY Safety Decals and Locations 4 5 6 18
SAFETY Safety Decals and Locations 4 6 (on rear of seat) 5 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control.
SAFETY Safety Decals and Locations 7 8 7 (Under Seat) ATTENTION Specific Operation of this vehicle without the air filter element carburetor jetting will severely damage the engine. and adjustments are required Clean pre-filter element often, more depending on temperature and frequent cleaning required altitude. See your Owner’s Manual. in dusty conditions. Do not Factory setting: operate vehicle without pre-filter. 40 to 80 F.
SAFETY Safety Decals and Locations 9 9 WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. 9 Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs 7170021 WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner’s Manual.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. See page 72 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 74 through 77. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 76. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. See page 77. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner’s Manual. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the correct size, type, and pressure as specified on page19. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner’s Manual. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.
CONTROLS AND FEATURES Controls Engine Electrical Switches 3 1 2 WARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death. 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped OFF RUN OFF with a reverse speed limiter system. To obtain additional power while backing up, depress the override button. NOTE: The 3 override switch also allows activation of AWD (All Wheel Drive) in reverse, if the AWD switch is on.
CONTROLS AND FEATURES Controls Engine Throttle and Choke WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.
CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir 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.
CONTROLS AND FEATURES Controls WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Front and Rear Brakes The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (1) on the top of the master cylinder.
CONTROLS AND FEATURES Controls Parking Brake WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated. Setting the Parking Brake 1. Put the vehicle gear selector into park. 2. Squeeze the left hand brake lever two or three times and hold it. 3. Push the park brake lock (2) into the notches on the master cylinder body. Release the brake lever. 4.
CONTROLS AND FEATURES Controls Foot Brake WARNING Use caution when applying the foot brake. Do not aggressively apply the foot brake when going forward or the rear wheels may skid and slide sideways causing loss of control. 1 Your Polaris ATV has a foot brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative.
CONTROLS AND FEATURES Controls Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. Refer to vehicle specifications on page 7 for tank capacity. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 (R+ M/2) octane. The fuel valve is located on the left side panel and has three positions: OFF: For vehicle storage and whenever transporting. ON: For normal operation. RES: For reserve supply in the event of main supply exhaustion.
CONTROLS AND FEATURES Controls Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck.
CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector The transmission gear selector is located on0 the right side of the vehicle directly above and forward of the engine and has five positions: high, low, neutral; reverse, and park. To shift into “High” or “Park”, you must first depress the foot brake to activate the High/Park lock out mechanism. When shifting out of “High” or “Park”, it is not necessary to depress the brake.
CONTROLS AND FEATURES Important Safeguards Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement. Avoid turning at sharp angles in reverse. Avoid backing on steep inclines. Light Switches and Indicator Lights WARNING This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways.
CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs are 1 equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off” the ATV is in 2 wheel drive at all times. When 2 the switch is “on” the ATV is in All Wheel Drive and the AWD indicator(2) will light. When in AWD, the front wheels will automatically engage anytime the rear wheels lose traction.
CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Engage the All Wheel Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the All Wheel Drive switch on. NOTE: If the instrument cluster is not registering a proper gear indication, AWD can still be enabled by pressing the mode/override button.
CONTROLS AND FEATURES Features Instrument Cluster Your Sportsman 700 is equipped with an instrument cluster which senses vehicle speed from the right hand front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed at approximately 7 to 9 mph. Refer to page 44 for additional information.
CONTROLS AND FEATURES Features Rider Information Center The rider information center is located in the lower portion of the instrument cluster. 1 Gear Indicator 4 5 As the shift lever is moved, this will indicate the gear the machine is in: H = High Range L = Low Range N = Neutral R = Reverse P = Park E or blank = Error 6 - Most of the time, 2 3 1 this error message will indicate you are inbetween gears. It can, however, also indicate the transmission switch is broken.
CONTROLS AND FEATURES Features Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button which is found on the LH handlebar is also the “mode button”. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse.
CONTROLS AND FEATURES Features Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance. When your vehicle leaves the factory, this feature is turned “OFF”. You must enable this feature if you intend to use it to track maintenance requirements. The service interval mode operates by service hours.
CONTROLS AND FEATURES Features Rider Information Center Diagnostic Mode CAUTION The diagnostic mode is for informational purposes only. Your dealer is fully equipped with the knowledge and special tools required to keep your machine running. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift the transmission to neutral. 3.
CONTROLS AND FEATURES Features Rider Information Center The second screen provides a full diagnostic indication of the entire oil pressure electrical circuit. Along with the letters PrSSr, there will be a box on the LH side. If the box is high, the pressure is normal. If the box is low, the pressure is low. Screen three is the tachometer for setting idle speed. If this needs adjustment, please contact your dealer. As long as you are in the diagnostic mode, the wrench icon will remain lit.
OPERATION Pre Ride Inspection WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3.
OPERATION Break-In Period The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. CAUTION Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil.
OPERATION Starting the Engine Procedure for Starting a Cold Engine WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result. 1. Place the transmission in neutral or park and reset the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Pull the choke out all the way. 5.
OPERATION Starting the Engine After the Engine Starts 1. If the engine slows or stops, use of the choke at half way in will allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in. Cold Weather Operation Polaris offers an engine heater kit for cold operation. If you use your ATV all year round, it is important to check your oil level frequently.
OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Maximum trailer weight - 1500 (680 kg) on level ground only with a maximum vertical hitch weight of 150 lbs. (68.04 kg). NOTE: The rear rack capacity and tongue weight should not exceed 180 lbs.
OPERATION Carrying Loads WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.
OPERATION Carrying Loads 68 LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS.
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S.
RIDING Pre Ride Inspection WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes foot brake) 4.
RIDING Safe Riding Tips Riding Position 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. 6.
RIDING Safe Riding Tips Making Turns Practice making turns at slow speeds. 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. The same leaning technique should be used for turning in reverse. WARNING Avoid turning at sharp angles in reverse as tipover and severe injury may result.
RIDING Safe Riding Tips Riding on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4.
RIDING Safe Riding Tips Traveling Uphill 25 Maximum WARNING Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (25 maximum). 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5.
RIDING Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle directions.
RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the foot brake and its use in the event loss of normal service brakes occurs. WARNING Do not travel at excessive speeds. It is dangerous and can cause loss of vehicle control and tipping, resulting in severe injury or death.
RIDING Safe Riding Tips Turning Around on a Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight uphill. 2. Leave transmission in forward and shut off engine. 3. Dismount on left or uphill side of ATV. 4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV). 5.
RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal. Avoid operating the ATV through deep or fast flowing water.
RIDING Safe Riding Tips Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.
RIDING Safe Riding Tips Backing Up 1. 2. 3. 4. 5. 6. Avoid backing up on steep inclines. Always back slowly. When in reverse, apply the brakes lightly for stopping. Avoid turning at sharp angles in reverse. Never open the throttle suddenly while backing. Never activate override button while throttle is open. Loss of control may result. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased.
RIDING Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 5. Shut off fuel supply.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart on the following pages. Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Miles Remarks Brake System Pre-ride Pre-ride Pre-ride inspection item Foot Brake Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bolts, fasteners Pre-ride Pre-ride Pre-ride inspection item Air Filter - Pre-Cleaner Pre-ride Pre-ride Inspect-Clean Coolant/Level Inspection P
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule CAUTION Due to the nature of the adjustments marked with a on the following chart, it is recommended that service be performed by an authorized Polaris dealer. More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Miles Remarks Oil Filter(4-Cycle) 100 hrs / 6 1000 months miles Replace with oil change Engine breather hose (4-cycle) 100 hrs 6 months Inspect Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage Throttle Cable/ETC Switch 50 hrs 6 months Inspect-adjust, lubricate, replace if necessary; preride inspection item Choke (Enricher) Cable 50 hrs 6 months Inspect, lubricate, repla
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule CAUTION Due to the nature of the adjustments marked with a on the following chart, it is recommended that service be performed by an authorized Polaris dealer. More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Miles Remarks Engine Mounts 100 hrs 12 months Inspect Valve Clearance 100 hrs 12 months Inspect/Adjust Brake fluid 200 hrs 24 months Change every two years Front wheel bearings 300 hrs 36 months Inspect, replace if necessary Idle Speed As Required As Required Adjust Toe adjustment As required As required Periodic inspection, adjust when parts are replaced Headlight Aim As required As required Ad
MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec Method Frequency* (1)Engine Oil Polaris Add to proper level on dip- Check level Premium stick. See page 96. daily. 4 Synthetic 0W40 (2) Brake Fluid DOT 3 Only Maintain level between fill lines. See page 47.
MAINTENANCE AND LUBRICATION Lubrication Recommendations (4) Front Gear Case Fill plug (5) Rear Gear Case (3) Transmission (plug) Fill plug (6) Front Prop Shaft (U-Joints) (7) Propshaft Yoke 89
MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) Front Drive Axle (U Joint) (AWD Models) (9) Ball Joint Grease+ Locate grease fitting and grease with grease gun. Grease ** Locate fitting on back side of Every 3 struts and grease with grease months or gun. 50 hours (10) Front A Arm Pivot Shaft Grease **∆ Locate fitting on pivot shaft and grease with grease gun. (11) Upper steering Post Bushing Grease ** Locate fitting on steering post Every 3 and grease with grease gun.
MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) Axle Cardan Front Drive (11) Steering Post Bushing (10) Front A Arm Pivot Shaft Upper (13) Lower Control Arm (12) Upper Control Arm (13) Lower Control Arm (15) Rear AntiRoll Bar (14) Rear Wheel Hub Bearing Carrier 91
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.
MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle(1), located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle. The engine coolant level is 1 controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.
MAINTENANCE AND LUBRICATION Engine Cooling System NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part. To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added.
MAINTENANCE AND LUBRICATION Lubrication 4-Cycle Premium 4 Synthetic Lubricant CAUTION Use only Polaris Premium 4 All Season synthetic oil or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines.
MAINTENANCE AND LUBRICATION Lubrication Oil and Filter Change 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Place vehicle on a level surface. Run engine two to three minutes until warm. Stop engine. Clean area around drain plug. Place a drain pan beneath engine crankcase and remove drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. Allow oil to drain completely. Replace sealing washer on drain plug.
MAINTENANCE AND LUBRICATION Lubrication Transmission Lubrication The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell. The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug (1) and check the lubricant level. Use the illustration and the chart below to determine the correct fluid level.
MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug is located as shown. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. With the ATV on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept 3/4” from the bottom of the fill plug thread. The correct gearcase lubricant to use is Premium Hub Fill plug Lube.
MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a level surface, remove the fill plug and visually inspect the lubricant level through the fill hole (1). The lubricant level should be maintained 1 5/8 in. from the top of the fill plug hole. Use GL5 80-90 weight gear lube. 1 2 Gearcase Oil Changing Procedure 1. Remove drain plug (2). Catch and discard used oil properly. 2. Clean and reinstall the drain plug with a new sealing washer and tighten securely (14 ft. lbs./1.
MAINTENANCE AND LUBRICATION Lubrication Oil System The oil dipstick and fill tube are located on the left side of the vehicle To check the oil: 1. Set machine on a level surface. A 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and lift the lever lock (A) on the dipstick. Remove the dipstick and wipe it clean. 4. Re-install the dipstick completely, remove it and read the oil level.
MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices. 1. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter. 2. If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.
MAINTENANCE AND LUBRICATION Filter Systems CAUTION Operation of your ATV without a breather filter can cause engine damage. Breather Filter and Hose 4-Cycle Engines With Dry Sump* 1. Take the filter(1) out of the hoses. 2. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging. Replace as needed. 3. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.
MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. WARNING If you determine your machine needs the tie rod adjusted for toe alignment, contact your dealer for service.
MAINTENANCE AND LUBRICATION Adjustments Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine. 4. Measure from string to rim at front and rear of front rim. Rear rim measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than front rim measurement. 5.
MAINTENANCE AND LUBRICATION Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer.
MAINTENANCE AND LUBRICATION Adjustments 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. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. To locate handlebar bolts, it will be necessary to remove the upper headlight pod. 2. Loosen the four bolts. 3.
MAINTENANCE AND LUBRICATION Adjustments Front Brake WARNING Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.
MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be changed when the friction material is worn to 3/64″ (.1 cm) which is about the thickness of a dime. Inspect the brake disc spline and pad wear surface for excessive wear.
MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes. A 2. Place the transmission in gear with the parking brake applied. 3. Adjust the carburetor idle screw (A) in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM.
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. Important Safeguards Maintain proper tire pressure according to the tire pressure decal. Improper tire inflation may affect ATV maneuverability. Do not use improper tires.
MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parking brake locked, 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. 2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4.
MAINTENANCE AND LUBRICATION Adjustments Tire Inspection When replacing a tire always use original equipment size and type. 1 Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) (1) or less.
MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation. Although this power cannot be regained, changes to the carburetor and drive system can be made to allow efficient operation.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement WARNING Keep your headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death. CAUTION Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Snap pins into tabs Position knob in slot and secure in locking tabs Slip O-Ring over pin Adjustment Knob Stop Route indicator harness over handlebar 1. Remove the three screws securing the headlight pod. 2. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Lift the pod lightly while depressing the tabs. 4. Lift pod cover up.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a 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.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Lift the pod lightly while depressing the tabs. 2. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Remove the three screws securing the headlight pod. O-Ring 4. Lift pod cover up. Disconnect instrument cluster harnesses from instrument cluster. Unplug indicator light harness and remove pod cover. 5.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lense cover and gasket and set aside for reassembly. 2. Remove lamp (A) and replace it with recommended lamp. 3. Test the taillight/brakelight to see that it’s working. 4. Reinstall the gasket and lens cover (B) removed in step 1.
MAINTENANCE AND LUBRICATION Spark Plugs Refer to page 7 for the correct spark plug for your machine. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. 1. Normal The insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded.
MAINTENANCE AND LUBRICATION Water Immersion CAUTION If your ATV becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected. If it is impossible to take it to a dealer before starting, follow the steps outlined below. Move the ATV to dry land or at the very least, to water below the foot rests. Turn the fuel valve off. Remove the spark plugs. Loosen the carburetor drain screw (1).
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury or death. Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. Because of the increased fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. Wear eye protection.
MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. 1 Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. 5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels.
MAINTENANCE AND LUBRICATION PVT System WARNING The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system remains safe: Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at high speeds. This system has been precision balanced.
MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed. For example, when operating at a ground speed of 3 MPH in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1200 - 1400 RPM.
MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs. High Range The following lists provide a guideline for when to use low range rather than high. Low Range: Basic operation at speeds less than 7 MPH Heavy pulling Riding through rough terrain (swamps, mountains, etc.
MAINTENANCE AND LUBRICATION Battery WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk.
MAINTENANCE AND LUBRICATION Battery Battery Removal 1. 2. 3. 4. 5. Remove the strap securing the battery. Remove the battery vent tube from the battery. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable next. Lift the battery out of the ATV, being careful not to tip it sideways and spill electrolyte. CAUTION If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.
MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, severe burns could result. 3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5.
MAINTENANCE AND LUBRICATION Side Panel Removal Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp 1 rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 2. Place hand on top of side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage the top 2 rear two tabs.
MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Cleaning - Outside...Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirt and grime. Don’t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts - use dish soap type cleaners only. High pressure washers may force water past seals. Drain the recoil housing. Stabilize Fuel - Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
MAINTENANCE AND LUBRICATION Cleaning and Storage * Fog The Engine - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use a section of clear 1/4″ hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Install the spark plug and pull the engine over slowly with the recoil starter. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
MAINTENANCE AND LUBRICATION Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn off the engine and remove the key. It may be lost if not removed. 2. Turn the fuel valve to off. 3. Be certain the fuel cap, oil cap, and seat are installed correctly. 4. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope. 5. Always place the transmission in park and lock the parking brake.
TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a pick- Shift transmission to low range during up or tall trailer when in high loading of the ATV to prevent belt burnrange. ing. Starting out going up a steep incline. When starting out on an incline, use low range, or dismount the ATV after first applying the park brake and perform the “K” turn as described on page 77 of this manual.
TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Climbing over large objects from a stopped position. Solutions/What to do Remove the drain plug at the lower rear portion of the clutch cover. Shift the transmission to Low Range, carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from water or Shift the transmission to neutral.
TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Clogged Fuel Valve or filter Boot not properly seated on plug.
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER Spark Plug Fouled No Fuel Turn Fuel Valve to “Res” Fuel Vent Line Kinked or Plugged Water in Fuel Air Filter Clogged Engine Overheated Clean Radiator screen and Radiator Core Reverse Speed Limiter Malfunction Electronic Throttle Control Malfunction Clean Engine Exterior Contact Your Dealer Contact Your Dealer Overuse of Choke 138
- NOTES - 139
WIRING DIAGRAM 140
WARRANTY LIMITED WARRANTY Polaris Industries 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 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. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
INDEX Accessories . . . . . . . . . . . . . . . . . . 114 Adjustments . . . . . . . . . . . . . . 104-114 Age Restrictions . . . . . . . . . . . . . . . . 3 Air Filter . . . . . . . . . . . . . . . . . . . . 102 All Wheel Drive . . . . . . . . . . . . . 54-55 Anti–Freeze . . . . . . . . . . . . . . . . . 133 Automatic Transmission . . . . . . . . . 52 Auxiliary Power Outlet . . . . . . . . . . 61 AWD . . . . . . . . . . . . . . . . . . . . . . 54-55 Backing Up . . . . . . . . . . . . . . . . . . .
INDEX Rider Information Center . . . . . . 57-61 RIDING . . . . . . . . . . . . . . . . . . . 70-81 Riding on Slippery Surfaces . . . . . . 73 Riding Position . . . . . . . . . . . . . . . . 71 Safe Riding Gear . . . . . . . . . . . . . . . 22 Safe Riding Tips . . . . . . . . . . . . . 71-81 SAFETY . . . . . . . . . . . . . . . . . . . . 9-16 Safety Decals and Locations . . . . 14-21 Safety Training . . . . . . . . . . . . . . . . . 3 Safety Decals . . . . . . . . . . . . . . . 15-43 Side Panel Removal . .
