Polaris MV700 User's Manual

WARNING
The engine exhaust from this
product contains chemicals known
to the State of California to cause
cancer, birth defects or
other reproductive harm.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
Copyright 2006 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2007 MV700 Owner’s Manual P/N 9921217
2
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . 62
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . 111
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 114
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . 124
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3
4
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification numbers in the spaces provided.
2
1
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
5
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious 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 and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
ATV safety training is a top priority for Polaris. When you purchased
your new ATV, your dealer instructed you on the authorized ATV
RiderCoursesm available to you and your eligible family members.
This training is included in the purchase price of your ATV. Polaris
strongly encourages you and your eligible family members who will be
riding the ATV to take the ATV RiderCoursesm. You were also
provided with printed materials that explain safe operating procedures.
You should review this information on a regular basis.
If you purchased a used Polaris ATV, you can take the ATV
RiderCoursesm by calling ATV Enrollment Express at (800) 887-2887
or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV
will be charged for this training.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
6
Operator Safety
SAFETY
The following signal words and symbols appear throughout this
manual and on your ATV. 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.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
7
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Purchasers of a new Polaris ATV and their eligible family
members are entitled to take the ATV RiderCoursesm. Contact ATV
Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for
information on enrollment in the ATV RiderCoursesm.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safety training course.
S Always avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
8
Operator Safety
SAFETY
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when possible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
9
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of accessories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
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.org, or call
Polaris at 1-800-342-3764.
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.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE:
10
The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the ATV
RiderCoursesm offered by Polaris through the SVIA. They should
then regularly practice the skills learned in the course and the
operating techniques described in the Owner’s Manual.
For more information about the ATV RiderCoursesm contact ATV
Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris ATV.
11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN HAPPEN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
WARNING
POTENTIAL HAZARD
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN HAPPEN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
12
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN HAPPEN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
14
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID THE
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
16
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never operate on hills too steep for the ATV or for your abilities.
Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for climbing
hills as described in the
owner’s manual.
Always check the terrain
carefully before ascending
any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
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.
18
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Traveling downhill
improperly.
WHAT CAN HAPPEN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for traveling
down hills as described in
the owner’s manual.
NOTE: A special technique
is required when braking
while traveling downhill.
See page 56.
Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill
when possible.
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN HAPPEN
Improperly crossing or
turning as hills could cause
loss of control or overturn.
HOW TO AVOID THE
HAZARD
Never 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 57. Use
extra caution when turning
on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a hill:
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
20
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards
or improperly dismounting
while climbing a hill.
WHAT CAN HAPPEN
The vehicle could overturn.
HOW TO AVOID THE
HAZARD
Maintain steady speed
when climbing a hill.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the ATV begins rolling backwards:
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill.
Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 57.
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
The ATV could collide with an obstacle or person, resulting in
severe injury.
HOW TO AVOID THE HAZARD
Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back slowly.
22
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which
could lead to an accident or overturn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable to enter water that exceeds the recommended
maximum depth (see page 58), travel slowly, balance your weight
carefully, avoid sudden movements, and maintain a slow and
steady forward motion. Do not make sudden turns or stops, and
do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for the ATV.
Always maintain proper tire pressure as specified.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of the ATV
may cause changes in handling which could lead to an accident.
HOW TO AVOID THE HAZARD
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. See your authorized Polaris
ATV dealer for more information.
WARNING
POTENTIAL HAZARD
Overloading the ATV or carrying/towing cargo improperly.
WHAT CAN HAPPEN
Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or 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 a
greater distance for braking.
Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 49.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the ATV and/or the operator
fall through the ice.
HOW TO AVOID THE HAZARD
Never operate the ATV on a frozen body of water.
24
Operator Safety
SAFETY
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
WARNING
Safe operation of this rider-active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturn and loss of control, which could result in severe injury or
death.
CAUTION
Exhaust system components are very hot during and after use of
the vehicle. Hot components can cause serious burns and fire.
Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system. Use
caution when traveling through tall grass, especially dry grass.
25
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Wearing a helmet can prevent a severe head
injury. Whenever riding a Polaris vehicle,
always wear a helmet that meets or exceeds
1
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
2
Oceania bear the ECE 22.05 label.
The ECE mark consists of
a circle surrounding the
5
letter E, followed by the
4
distinguishing number of
the country which has
051039
granted approval. The
0006.031
approval number and serial
number will also be
displayed on the label.
3
E
4
2. 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.
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
26
CONTROLS
Electrical Switches
WARNING
Activating the override switch while the throttle is open can cause
loss of control, resulting in severe injury or death. Do not activate
the override switch while the throttle is open.
6
5
4
2
1
3
Mode/Reverse Override Switch (1) - This vehicle is equipped with a
reverse speed limiter system. To gain additional power while backing,
depress the override switch. The override switch also allows activation
of AWD in reverse, if the AWD switch is on. This switch is also used
to toggle through the different modes of the rider information center.
See page 38.
Engine Stop Switch (2) - The engine will not
start or run when the switch is in the OFF position.
Its purpose is to provide the operator with a
quick means of engine shutdown in case of an
emergency.
2
Ignition Switch Lever (3) - To start the engine, slide the stop switch
to the center RUN position and turn the ignition switch lever clockwise
past the ON position. Release the lever when the engine starts.
NOTE:
Both the ignition switch and the emergency engine stop
switch will shut off all electrical power to the vehicle,
including lights. To stop the engine, slide the stop switch
either right or left to the OFF position.
Infrared Light Switch (4) - Use this switch to activate the infrared
lights (if equipped). When the infrared lights are turned on, all other
lights on the vehicle are turned off.
Front/Rear Winch Switch (5) - Use the switch on the pod to select
either the front or rear winch.
Winch Operation Switch (6) - After selecting either the front or rear
winch with the switch on the pod, use the handlebar switch to operate
the winch. Operation instructions can be found in the winch operation
guide provided by the winch manufacturer.
27
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. Always check the lever for free movement and return
before starting the engine. Also check occasionally during
operation.
Throttle Lever
Engine speed and vehicle
movement are controlled by
pressing the throttle lever (1). The
throttle lever is spring loaded.
Engine speed returns to idle when
the lever is released.
This ATV is equipped with Polaris
1
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.
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.
28
Light Switches
CONTROLS
The light switch is located on the left handlebar. It’s used to turn the
lights on and off and to switch the lights from HI to LO. To operate the
lights, the ignition switch lever must be in the ON position and the stop
switch must be in the RUN position.
WARNING
Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness.
Brake Lever
The front and rear brakes are applied
1
by squeezing the brake lever (1)
toward the handlebar. The front and
rear brakes are hydraulically
activated disc type brakes that are
activated by only one lever.
Always test brake lever travel and
master cylinder fluid level before riding.
When squeezed, the lever should feel firm. Any sponginess would
indicate a possible fluid leak or low master cylinder fluid level, which
must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
WARNING
Operating the ATV with a spongy brake lever can result in loss of
braking, which could cause an accident.
Never operate the ATV with a spongy-feeling brake lever.
29
CONTROLS
Master Cylinder
The brake fluid in the master
cylinder (1), which is located on the
left handlebar, should be checked
before each ride. The fluid level
can be seen through an indicator
window (2) on the top of the master
cylinder. This eye will appear dark
when the fluid level is full. When
fluid needs to be added, the eye will be clear.
NOTE:
1
2
When checking the fluid level, the ATV must be on level
ground with the handlebars straight. If the fluid level is low
add DOT 4 brake fluid only. See page 111 for the part
numbers of Polaris products.
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury.
30
Parking Brake
CONTROLS
WARNING
Operating the ATV while the parking brake is engaged could
result in an accident and serious injury or death. Always check to
be sure the parking brake is disengaged before operating.
Locking the Parking Brake
1
1. Place the transmission in
PARK.
2. Squeeze and release the
brake lever two or three
times, then squeeze and
hold.
3. Push the park brake lock (1)
forward to engage the
brake. Release the brake
lever.
4. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
Important Safeguards
S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill
position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
31
CONTROLS
Auxiliary Brake
WARNING
Aggressively applying the auxiliary brake when backing down a
hill may cause rear tipover, which could result in serious injury or
death.
Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward. The
rear wheels may skid and slide sideways, causing loss of control
and serious injury or death.
Your Polaris ATV has an
auxiliary brake (1) for added
safety. It’s located on the
inside of the right floor
board and is operated by the
right foot. The auxiliary
brake serves as a backup to
the main brake system if the
main system becomes
inoperative.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
1
Brake Fluid Level
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat or near the auxiliary brake.
Maintain the fluid level between the maximum and minimum marks.
32
CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 47 for correct choke and throttle settings during
starting.
Fuel Requirements
Use either leaded or unleaded gasoline with a minimum pump octane
number of 87=(R+ M/2) octane.
Fuel Valve
The fuel valve (1) is located on the
left side panel.
OFF: Turn the fuel valve off for
vehicle storage and when transporting.
REAR TANK: We recommend using
the rear tank fuel supply first. Switch
to the front tank when the rear tank is
empty. It will be easier to monitor
remaining fuel at the front tank gauge.
FRONT TANK: Use the front
tank fuel supply when the rear
tank is empty.
NOTE:
REAR
TANK
OFF
FRONT
TANK
2
1
There is no reserve fuel
supply on this vehicle. When
both fuel tanks are empty, the
vehicle will not operate.
Fuel Tanks
The front fuel tank filler cap (2) is
located directly below the
handlebar. The rear fuel tank and
filler cap (3) are located behind
the seat, under the rear rack.
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after every
100 hours of operation, or
annually. Do not attempt to clean
the fuel filter.
3
33
CONTROLS
Automatic Transmission Gear Selector
The transmission gear
selector (1) is located on
the right side of the
vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
1
H
L
N
R
P
To shift into HIGH or PARK,
apply the auxiliary brake to
activate the high/park lock-out
mechanism. When shifting out
of HIGH or PARK, it’s not necessary to apply the brake.
CAUTION
Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear. Apply the auxiliary brake
before shifting into HIGH or PARK.
Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour for extended periods of
time.
34
Recoil Starter
FEATURES
2
If the battery has been drained or
damaged and cannot start the
1
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side of
the machine.
Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes recoil
starting possible by reducing the
amount of compression during starting.
The decompressor senses when the engine is spinning
fast enough to start and restores compression when running.
1. Position the vehicle on a level surface.
2. Lock the parking brake.
3. Shift the transmission into neutral.
4. Move the engine stop switch to RUN and the ignition switch lever
to ON.
NOTE:
If the engine is cold, use the choke as outlined on page 47.
5. Grasp the recoil starter rope handle (2) firmly and pull slowly so
you can feel the engine strokes.
NOTE:
Every other stroke will be a “compression stroke” and will
make the rope harder to pull. When a compression stroke is
found, continue pulling the rope just until the engine rolls past
the stroke, then stop pulling immediately.
6. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
7. Repeat steps 5-6 if necessary.
CAUTION
Extending the recoil starter rope until it stops can cause damage
to the recoil assembly. Do not extend the starter rope so far that
it stops.
If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.
35
FEATURES
Run-Flat Tires
This ATV is equipped with run-flat tires, which permit limited
operation with a flat tire. However, ATV load capacity is reduced when
tire air pressure is lost. Remove cargo from the racks and do not tow a
load with flat tires. Vehicle characteristics, including braking and
handling, may also be affected by operating with flat tires. If you must
operate the vehicle with a flat tire, drive no further and no faster than
necessary, and travel on smooth and level terrain whenever possible.
WARNING
Failure to reduce travel distance, vehicle speed and cargo weight
when air pressure is lost in run-flat tires could result in loss of
control or tire damage. This could lead to serious injury or death.
If you must operate the vehicle with flat tires, remove all cargo
and towed loads from the ATV, and do not exceed 50 miles (80
km) at 25 MPH (40 km/h).
Have the tire(s) inspected by an authorized Polaris dealer as
soon as possible and before further use.
Winches
Your vehicle is equipped with
both a front (1) and a rear (2)
winch. These winches operate
independently. Use the pod
switch to select one of the
winches. Use the handlebar
switch to operate the selected
winch.
Refer to the winch
manufacturer’s Basic Guide to
Winching Techniques,
provided with your ATV, for
complete winch operation
instructions.
36
2
1
All Wheel Drive (AWD) System
FEATURES
Polaris 4-wheel drive ATVs
are equipped with a unique,
Polaris-exclusive, All Wheel
Drive (AWD) system, which
is activated by a switch (1)
on the right handlebar.
1
When the switch is off, the
ATV is in 2-wheel drive at all
times. When the switch is on, the
ATV is in AWD and the AWD indicator light in the instrument cluster
will be on.
When in AWD, the demand drive unit will automatically engage any
time the rear wheels lose traction. When the rear wheels regain
traction, the demand drive unit will automatically disengage.
NOTE:
The override switch allows activation of AWD in reverse if the
AWD switch is on. See page 27.
There is no limit to the length of time the vehicle may remain in AWD.
Engaging All-Wheel Drive (AWD)
The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle’s electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.
Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning may cause
severe drive shaft and gearcase damage. Always switch to AWD
while the rear wheels have traction or are at rest.
37
FEATURES
Instrument Cluster
Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster measures
distance in miles or kilometers as well as hours of operation. It also
includes a reverse speed limiter function that limits the ATV’s speed to
approximately 7-9 mph. Refer to page 27 for additional information.
3
2
1
1. Rider Information Center
2. Speedometer needle - in addition to showing vehicle speed, the
needle flashes when a warning condition exists.
3. Speedometer
CAUTION
High water pressure may damage ATV components. Wash the
ATV by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not
use alcohol to clean the instrument cluster. Do not allow insect
sprays to contact the lens. Immediately clean off any gasoline
that splashes on the instrument cluster.
38
Instrument Cluster
FEATURES
Rider Information Center
The rider information center is located in the instrument cluster. All
segments will light up for 2.5 seconds at start-up.
NOTE:
If the instrument cluster fails to illuminate, a battery
over-voltage may have occurred and the instrument cluster
may have shut off to protect the cluster’s electrical system. If
this occurs, take the ATV to your Polaris dealer for proper
diagnosis.
1. Gear Indicator - This
indicator displays gear
shifter position:
4
5
6
3
H = High Range
7
L = Low Range
N = Neutral
8
2
R = Reverse
P = Park
2. AWD Indicator - This
indicator illuminates
when the AWD switch is
9
in the AWD position.
1
3. Engine Hour Display Indicator
4. Service Interval/Diagnostic Mode Indicator
5. Low Battery and Over Voltage - This warning usually indicates
that the ATV is being operated at an RPM too low to keep the
battery charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Drive at a higher RPM or
recharge the battery to clear the warning.
6. Odometer/Tachometer/Tripmeter/ Hour Meter
7. Fuel Gauge - The segments of the fuel gauge indicate the level of
fuel in the front tank only. Since use of the rear tank is
recommended for normal operation, the rear tank may already be
empty. Refuel immediately if the last segment of the fuel gauge
clears.
8. Check Engine Warning Indicator - The word HOT displays if
the engine overheats. Do not operate the ATV if this warning
appears. Serious engine damage could result
9. Mode Indicator
39
FEATURES
Instrument Cluster
Rider Information Center
Standard Modes
Use the MODE button to toggle through the mode options. The reverse
override button is also the MODE button. See page 27.
NOTE:
The transmission cannot be in reverse when using this
feature.
Odometer Mode
The odometer records the miles traveled by the ATV.
Trip Meter Mode
The trip meter records the miles traveled by the ATV on each trip if it’s
reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the total
changes to 0.
NOTE:
In the Rider Information Center, the trip meter display
contains a decimal point, but the odometer displays without a
decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Tachometer Mode
The engine RPM is displayed digitally.
NOTE:
40
Small fluctuations in the RPM from day to day may be
normal because of changes in humidity, temperature,
elevation and electrical loads.
Instrument Cluster
FEATURES
Rider Information Center
Diagnostic Mode
The wrench icon will display when the gauge is in the diagnostic
mode. To exit the diagnostic mode, turn the ignition switch off and on.
Any movement of the tires will also cause the gauge to exit the
diagnostic mode.
To enter the diagnostics mode:
1. Turn the ignition switch off and wait 10 seconds.
2. Lock the parking brake.
3. Place the transmission in neutral.
4. Hold the mode/reverse override button and turn the ignition switch
on. Release the switch as soon as the display is activated.
5. Use the mode button to toggle through the diagnostic screens.
41
FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Mode
Battery Voltage Screen
View this screen to check battery voltage level.
Tachometer Screen
View the tachometer to check engine speed.
AWD Diagnostic Screen
The gauge indicates whether or not current is flowing through the
AWD coil (only on models with switchable AWD). This screen is for
informational purposes only. Please see your dealer for all major
repairs.
Gear Circuit Diagnostic Screen
This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge. This screen is for informational
purposes only. Please see your dealer for all major repairs.
Programmable service interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 43.
NOTE:
42
The service interval is programmed at 50 hours at the
factory.
Instrument Cluster
FEATURES
Rider Information Center
Diagnostic Mode
Programmable service interval
To enable or disable the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for about 7 seconds, until either
ON or OFF appears in the Rider Information Center, depending on
your preference.
To reset the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for 2--3 seconds, until the wrench
icon flashes. Release the button.
4. Press and release the mode button once to advance the setting by
one hour. Press and hold the mode button to advance the hours
quickly.
NOTE:
If you scroll past the intended number, press and hold the
button until the hours cycle back to zero.
5. When the desired setting is displayed, wait until the wrench icon
stops flashing. The new service interval is now programmed.
Miles/Kilometers toggle
The display in the tripmeter and odometer can be changed to display
either standard or metric units of measurement.
1. Enter the diagnostic mode.
2. Toggle to the screen that displays either kilometers (KM) or miles
(MP).
3. Press and hold the mode button until the letters flash, then press
and release the button once. When the display stops flashing, the
mode has been set.
43
OPERATION
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
S Never start the engine or let it run in an enclosed area. Engine exhaust fumes
are poisonous and can cause loss of consciousness or death in a short time.
S Turn the fuel valve off whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
44
Break-In Period
OPERATION
The break--in period for your new Polaris ATV is the first ten hours of
operation, or the time it takes to use the first two full tanks of gasoline.
No single action on your part is as important as following the
procedures for a proper break--in. Careful treatment of a new engine
and drive components will result in more efficient performance and
longer life for these components.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.
Engine and Drivetrain Break-in
1. Fill the fuel tanks with gasoline. See page 33.
2. Check the oil reservoir level on the dipstick. See page 70. Add
oil if necessary to maintain the level between the safe and add
marks.
3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 46.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 20
hours or one month.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer
life and better performance. Break in the clutches and belt by operating
at slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation
during the break-in period
45
OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury
or death could result. Always inspect the vehicle before each use
to ensure it’s in proper operating condition.
Pre-Ride Checklist
Item
Remarks
See
Page
Brake system / lever travel
Ensure proper operation
29, 80
Brake fluid
Ensure proper level
30
Auxiliary brake
Ensure proper operation
32
Front suspension
Inspect, lubricate if necessary
68
Rear suspension
Inspect, lubricate if necessary
68
Steering
Ensure free operation
Tires
Inspect condition and pressure
83
Wheels / fasteners
Inspect, ensure fastener tightness
84
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
70
Coolant level (if applicable)
Ensure proper level
--
Coolant hoses (if applicable)
Inspect for leaks
Throttle
Ensure proper operation
Indicator lights / switches
Ensure operation
29
Engine stop switch
Ensure proper operation
27
Air filter, pre-filter
Inspect, clean
85
Air box sediment tube
Drain deposits whenever visible
Headlamp
Check operation, apply Polaris dielectric grease when lamp is replaced
Check operation, apply Polaris dielectric grease when lamp is replaced
Wear helmet, goggles, protective
clothing
Brake light / tail lamp
Riding gear
46
--
--
-28,103
-86
89
26
Starting the Engine
OPERATION
WARNING
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness resulting in severe injury or death.
Never run an engine in an enclosed area.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
3. Lock the parking brake.
NOTE:
The starter interlock will prevent the engine from starting if
the transmission is in gear and the brake is not engaged.
4. Turn the fuel valve on.
5. Sit on the vehicle.
NOTE:
Do not use the choke if starting a warm engine. Excessive
use of the choke can cause the spark plug to become wet
fouled.
6. If the engine is cold, pull the
choke knob (1) out until it stops.
NOTE:
The variable choke is fully on
when the knob is pulled
completely out. The choke is off
when the knob is pushed
completely in. The choke can
be adjusted gradually,
depending on how much
choke is needed for starting. Be
1
sure the choke is off during
operation, as excess fuel washing into
the engine oil will increase wear on engine components.
NOTE:
If the knob doesn’t stay where positioned, increase the
tension by rotating the tension adjusting nut clockwise.
7. Move the engine stop switch to RUN.
NOTE:
Do not press the throttle while starting the engine.
47
OPERATION
Starting the Engine
8. Turn the ignition lever past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
lever when the vehicle starts.
9. If the engine does not start, return the ignition lever to the OFF
position and wait five seconds. Activate the starter for another five
seconds if necessary. Repeat this procedure until the engine starts.
NOTE:
If a warm engine has cooled to a point where it does not
readily start, intermittent use of the choke button (pulled half
way out) may be necessary. If the engine is over-choked
when warm, depress the throttle lever fully while cranking to
aid in starting. Release the throttle lever immediately after
the engine starts. If the engine does not start and all
conditions are favorable, change the spark plug and try
again.
10. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm-up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.
CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminants such as water
or excess fuel in the crankcase. Water in the crankcase can lead to
engine damage and must be drained. Water accumulation increases as
outside temperature decreases.
See your Polaris dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.
48
Hauling Cargo
1/3
OPERATION
2/3
Do not exceed the weight capacities specified for the vehicle. Cargo
weight should be evenly distributed (1/3 on the front rack and 2/3 on
the rear rack) and mounted as low as possible. When operating over
rough or hilly terrain, reduce speed and cargo weight to maintain stable
driving conditions. Do not obstruct the headlight beam with cargo.
Use low forward gear when hauling or towing heavy cargo to extend
belt life.
Refer to the specifications section beginning on page 112 for capacities.
Towing Loads
Always attach a towed load to the hitch point. If towing a load, reduce
rear rack cargo weight by the amount of tongue weight. The
combination of rear rack cargo weight and tongue weight must not
exceed the rear rack capacity. See page 112.
Maximum Towing Capacities
Towed Load (Level Ground)
1500 lbs. (681 kg)
Towed Load (15_ Incline)
850 lbs. (386 kg)
Vertical Hitch Weight
150 lbs. (68.1 kg)
49
OPERATION
Hauling Cargo
WARNING
Overloading the vehicle or carrying or towing cargo improperly
can alter vehicle handling and may cause loss of control or brake
instability, which can result in serious injury or death. Always
follow these precautions when hauling cargo:
S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and
2/3 on the rear rack. When operating over rough or hilly terrain, reduce
speed and cargo to maintain stable driving conditions. Carrying loads
on one rack only increases the possibility of vehicle overturn.
S CARRY LOADS 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.
S SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can
create unstable operating conditions, which could result in loss of control of the vehicle.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS.
When handling off-centered loads that cannot be centered, securely
fasten the load and operate with extra caution. Always attach the tow
load to the hitch point designated for your vehicle.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS.
Use extreme caution when applying brakes with a loaded vehicle.
Avoid terrain or situations that may require backing downhill.
S USE EXTREME CAUTION when operating with loads that extend over
the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying
loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
Vehicle should never exceed 10 mph (16 kph) while towing a load on a
level surface. Vehicle speed should never exceed 5 mph (8 kph) when
towing loads in rough terrain, while cornering, or while ascending or
descending a hill.
50
Driving Procedures
OPERATION
1. Wear protective riding gear. See page 26.
2. Sit upright with both feet on the footrests and both hands on the
handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the parking brake.
7. Slowly depress the throttle with your right thumb and begin
driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
51
OPERATION
Making Turns
Your ATV is equipped with a rear
axle that 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. This technique alters
the balance of traction between the
rear wheels, allowing the turn to be
made smoothly. The same leaning
technique should be used for turning
in reverse.
NOTE:
Practice making turns at slow speeds before attempting to
turn at faster speeds.
WARNING
Turning at sharp angles or at excessive speeds can result in
vehicle overturn and lead to serious injury. Avoid turning at sharp
angles. Never turn at high speeds.
52
Driving on Slippery Surfaces
OPERATION
Whenever riding on slippery
surfaces such as wet trails or
loose gravel, or during
freezing weather, follow these
precautions:
1. Slow down when
entering slippery areas.
2. Engage AWD before
wheels begin to lose
traction.
3. Maintain a high level
of alertness, reading the
trail and avoiding quick,
sharp turns, which can cause
skids.
4. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body weight forward.
CAUTION
Severe damage to drive train may occur if the AWD is engaged
while the wheels are spinning. Always allow the rear wheels to
stop spinning before engaging AWD, or engage AWD before
wheels begin to lose traction.
WARNING
Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.
Never apply the brakes during a skid. Do not operate on
excessively slippery surfaces. Always reduce speed and use
additional caution.
53
OPERATION
Driving Uphill
25_ Maximum
Whenever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25_ maximum).
3. Keep both feet on the footrests.
4. Shift your weight uphill.
5. Proceed at a steady rate of speed and throttle opening.
6. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
WARNING
Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
54
Driving on a Hillside (Sidehilling)
OPERATION
WARNING
Improperly crossing hills or turning on hills can result in loss of
control or vehicle overturn, resulting in severe injury or death.
Avoid crossing the side of a hill when possible. Follow proper
procedures as outlined in the owner’s manual.
Sidehilling can be dangerous and should be avoided if at all possible.
If you encounter a situation where sidehilling is necessary, follow these
precautions:
1. Slow down.
2. Shift your weight uphill.
3. Keep your feet on the footrests.
4. Steer slightly into the hill to maintain vehicle direction.
NOTE:
If the vehicle begins to tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side
immediately!
55
OPERATION
Driving Downhill
WARNING
Excessive speed when traveling downhill can cause loss of
control and serious injury or death. Slow down.
Applying the brakes too firmly may cause the rear wheels to lock,
which could result in loss of control and serious injury or death.
Apply the brakes gradually.
When driving downhill, follow these precautions:
1. Shift your weight uphill.
2. Drive straight downhill.
3. Slow down.
4. Squeeze the brake lever gradually.
NOTE:
56
Before operating your ATV, learn how to use the auxiliary
brake for emergency situations (if single-lever brakes
become inoperable).
Turning Around on a Hill
OPERATION
If the vehicle stalls while climbing a hill, never back down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
1. Stop the vehicle and lock the parking brake while keeping body
weight uphill.
2. Leave the transmission in forward and stop the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the service brake, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.
6. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
7. Restart the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the service brake, until the vehicle is on more level ground.
57
OPERATION
Driving Through Water
Your ATV can operate through
water with a maximum
recommended depth equal to
the bottom of the footrests (1).
Follow these procedures when
operating through water:
1. Determine water depths
and current before
crossing.
1
2. Choose a crossing where
both banks have gradual
inclines.
3. Proceed slowly, avoiding rocks and obstacles.
4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 63. The following areas
need special attention: engine oil, transmission oil, demand drive
fluid, rear gearcase oil and all grease fittings.
CAUTION
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart.
If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service before
starting the engine.
NOTE:
Avoid operating the vehicle through deep or fast-flowing
water. If you cannot avoid water that exceeds the
recommended maximum depth, go slowly, balance your
weight carefully, avoid sudden movements, and maintain a
slow and steady forward motion. Do not make sudden turns
or stops, and do not make sudden throttle changes.
If your vehicle becomes immersed, and it’s impossible to take it to a
dealer before starting it, follow the steps described on page 92. Have
the vehicle serviced by your dealer at the first opportunity.
58
Driving Over Obstacles
OPERATION
Be alert! Look ahead and learn to read the terrain you’re traveling on.
Be constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact
with a hidden obstacle. Not all obstacles are immediately visible.
Travel with caution in unfamiliar terrain.
59
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for
obstacles or people
behind the vehicle.
2. Always avoid
backing downhill.
3. Back slowly.
4. Apply the brakes
lightly for stopping.
5. Avoid turning at sharp
angles.
6. Never open the throttle suddenly.
WARNING
Failure to use caution when operating in reverse can result in
serious injury or death. Before shifting into reverse, always check
for obstacles or people behind the vehicle. When it’s safe to
proceed, back slowly.
Do not use the override switch unless additional power is required
for vehicle movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
NOTE:
Your Polaris ATV is equipped with a reverse speed limiter.
The override button should be used with caution as rearward
vehicle speed is greatly increased. Do not operate at wide
open throttle. Open the throttle just enough to maintain a
desired speed.
CAUTION
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
60
Parking on an Incline
OPERATION
Avoid parking on an incline if possible. If it’s unavoidable, follow
these precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
61
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 USDA Forest Service Standard 5100-1C.
Federal law requires that this spark arrestor be installed and functional
when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343. Violations are subject to monetary penalties.
Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
All exhaust gases exit through the exhaust system.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine
and related components must be maintained at Polaris specifications to
achieve optimal performance.
Adjustment to engine idle is the only adjustment Polaris recommends
that the operator perform. Any other adjustments should be performed
by an authorized Polaris dealer.
The emissions label is located on the air box.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES--002.
This vehicle complies with European directives 97/24/EC and
89/336/EEC.
62
Periodic Maintenance Chart
MAINTENANCE
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
NOTE:
Service and adjustments are important for proper vehicle
operation. If you’re not familiar with safe service and
adjustment procedures, have a qualified dealer perform
these operations.
Maintenance intervals in the following chart 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.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause or see your dealer.
63
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
"
E
J
Perform these procedures more frequently for vehicles subjected to
severe use.
Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
64
Periodic Maintenance Chart
MAINTENANCE
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
J Steering
--
Pre-Ride
--
" Front suspension
--
Pre-Ride
--
" Rear suspension
--
Pre-Ride
--
Tires
Remarks
Make adjustments
j
as needed See Pre
ed.
Pre-Ride
Ride Checklist
on page 46.
--
Pre-Ride
--
" Brake fluid level
--
Pre-Ride
--
" Brake lever travel
--
Pre-Ride
--
Brake system
--
Pre-Ride
--
Wheels/fasteners
--
Pre-Ride
--
Frame fasteners
--
Pre-Ride
--
" Engine oil level
--
Pre-Ride
--
" Air filter, pre-filter
--
Daily
--
Inspect; clean often
" Air box sediment
--
Daily
--
Drain deposits when visible
Coolant
--
Daily
--
Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
--
Daily
--
Check operation
--
Weekly
--
Inspect; replace as needed
--
Weekly
--
Drain water as needed,
check often if operating in
wet conditions
10 H
Monthly
100 (160)
Inspect periodically
E
tube
" Air filter,
E main element
Recoil housing
" Brake pad wear
J
20 H
Monthly
200 (320)
Check terminals; clean; test
" Demand drive
Battery
25 H
Monthly
250 (400)
Inspect level; change yearly
" Rear gearcase oil
25 H
Monthly
250 (400)
Inspect level; change yearly
" Transmission oil
25 H
Monthly
250 (400)
Inspect level; change yearly
" Engine breather
25 H
Monthly
250 (400)
Inspect; clean if needed
fluid
E filter (if equipped)
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
"
65
MAINTENANCE
Periodic Maintenance Chart
Item
" General
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
50 H
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
50 H
6M
500 (800)
Drain bowl periodically and
prior to storage
J Throttle Cable/
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
J Choke cable
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
50 H
6M
500 (800)
Inspect ducts for proper
sealing/air leaks
Drive belt
50 H
6M
500 (800)
Inspect; adjust; replace as
needed
Cooling system
50 H
6M
1000 (1600)
Inspect coolant strength
seasonally; pressure test
system yearly
" Engine oil change
100 H
6M
1000 (1600)
Perform a break-in oil
change at one month
" Oil filter change
100 H
6M
1000 (1600)
Replace with oil change
J Valve clearance
100 H
12 M
1000 (1600)
Inspect; adjust
J Fuel system/filter
100 H
12 M
1000 (1600)
" Radiator
100 H
12 M
1000 (1600)
Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
Inspect; clean external
surfaces
" Cooling hoses
100 H
12 M
1000 (1600)
Inspect for leaks
" Engine mounts
100 H
12 M
1000 (1600)
Inspect
100 H
12 M
1000 (1600)
Inspect
lubrication
Carburetor float
bowl
E ETC Switch
E
E Carburetor air
intake ducts/
flange
E
E
(if applicable)
(if applicable)
Exhaust muffler/
pipe
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
"
66
Periodic Maintenance Chart
Item
MAINTENANCE
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
J Spark plug
100 H
12 M
1000 (1600)
Inspect; replace as needed
J Ignition Timing
100 H
12 M
1000 (1600)
Inspect
" Wiring
100 H
12 M
1000 (1600)
J Clutches (drive
100 H
12 M
1000 (1600)
Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Inspect; clean; replace worn
parts
J Front wheel
100 H
12 M
1000 (1600)
Inspect; replace as needed
J Brake fluid
200 H
24 M
2000 (3200)
Change every two years
300 H
36 M
3000 (4800)
Clean out
E
E
and driven)
bearings
Spark arrestor
Winch System
--
Refer to the operator’s guide
provided by the winch
manufacturer.
E Idle speed
--
Adjust as needed
J Toe adjustment
--
Inspect periodically; adjust
when parts are replaced
--
Adjust as needed
Headlight aim
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
"
67
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 63. Items not listed in
the chart should be lubricated at the General Lubrication interval.
Item
Lube
Method
Engine Oil
Polaris Premium 4 Synthetic
0W40
Add to proper level on dipstick.
Brake Fluid
DOT 4 Only
Maintain level between fill
lines. See page 30.
Transmission Oil
Polaris AGL Synthetic
Gearcase Lube
See page 74.
Demand Drive Fluid
(Front Gearcase)
Demand Drive LT Premium Fluid
See page 73.
Rear Gearcase Oil
Premium ATV Angle Drive Fluid
See page 75.
General Lubrication
Polaris Premium All Season
Grease
Front Prop Shaft Yoke
(Fig. 1)
Polaris Premium U--Joint Lube
Grease fittings (3 pumps
maximum) every 500 miles,
before long periods of storage, or after pressure washing or submerging.
(Fig. 1)
68
MAINTENANCE
Premium 4 Synthetic Lubricant
Polaris Premium 4 All Season synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection. See page 111 for the part
numbers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. (-40 to
+49° C.) Its exceptional frictional properties result in more efficient
operation, more power output and lower fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified SH oil is allowable as long as it’s
0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 synthetic Oil or another 0W-40 API certified SH oil.
Never substitute or mix oil brands.
69
MAINTENANCE
Oil Check
The dipstick/oil fill (1) is located on the engine on the left side of the
ATV. Do not start the engine before the oil check.
NOTE:
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.
1. Position the vehicle on a level surface.
2. Remove the dipstick and wipe it dry
with a clean cloth.
NOTE:
Lift the lever lock (2) to remove
the dipstick.
3. Reinstall the dipstick completely, but
do not lock it. The dipstick must be
completely seated.
4. Remove the dipstick
and check the oil level.
Maintain the oil level
2
between the SAFE
and ADD marks (3).
Do not overfill.
NOTE:
Due to the dipstick
entry angle into the
crankcase, the oil level
will read higher on the
bottom side of the dipstick.
Always read the level on
the upper surface (4) of
the dipstick.
5. After reinstalling the dipstick,
seat the lever lock.
70
1
ADD 8 OZ
SAFE
3
4
Oil and Filter Change
MAINTENANCE
Change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 63. Always install a new filter
when changing the oil.
1. Position the vehicle on a level surface.
2. Run the engine for two to three minutes until warm. Stop the
engine.
3. Clean the area around the drain plug.
4. Place a drain pan beneath engine crankcase and remove the drain
plug.
CAUTION
Hot oil can cause serious burns. Do not allow hot oil to touch
skin.
5. Allow the oil to drain completely.
6. Replace the sealing washer on the drain plug.
NOTE:
The sealing surfaces on drain plug and crankcase should be
clean and free of burrs, nicks or scratches.
7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm).
8. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter counterclockwise to remove.
9. Using a clean dry cloth, clean the filter sealing surface on the
crankcase.
10. Lubricate the o-ring on the new filter with a film of fresh engine
oil. Check to make sure the o-ring is in good condition.
11. Install the new filter and turn by hand until the filter gasket
contacts the sealing surface, then turn and additional 1/2 turn.
12. Remove the dipstick and fill the sump with two quarts (1.9 l) of
recommended oil.
13. Place the gear selector in PARK and set the parking brake.
14. Start the engine and let it idle for one to two minutes. Stop the
engine and inspect for leaks.
15. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.
16. Dispose of used filter and oil properly.
71
MAINTENANCE
Gearcase Specification Chart
Gearcase
Lubricant
Capacity
Fill Plug
Torque
Drain
Plug
Torque
Main
Gearcase
(Transmission)
Premium
AGL
Synthetic
Gearcase
Lube
15.2 oz.
(450 ml)
14 ft. lbs.
(19 Nm)
14 ft. lbs.
(19 Nm)
Demand Drive
Unit (Front
Gearcase)
Demand
Drive LT
Premium
Fluid
9 oz.
(265 ml)
8-10 ft. lbs.
(11-14 Nm)
11 ft. lbs.
(15 Nm)
Rear
Gearcase
Premium
ATV Angle
Drive Fluid
10 oz.
(300 ml)
Side plug
16 ft. lbs.
(22 Nm)
14 ft. lbs.
(19 Nm)
72
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Always check and change the demand drive fluid at the intervals
outlined in the Periodic Maintenance Chart beginning on page 66.
We recommend the use of Demand Drive LT Premium Fluid. Use of
other fluids may result in improper operation of components.
Refer to the Gearcase Specifications Chart on page 72 for
recommended lubricants, capacities and torque specifications. See page
111 for the part numbers of Polaris products.
The fill plug (1) is
1
located on the right side
of the demand drive
unit. The drain plug (2)
is located on the bottom
right side of the unit.
Maintain the fluid level
at the bottom of the fill
hole threads (3).
3
Fluid Check
2
1. Position the vehicle on a level surface.
2. Remove the fill plug. Check the fluid level.
3. Add the recommended demand drive fluid as needed to bring the
level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to specification.
Fluid Change
1.
2.
3.
4.
5.
6.
7.
8.
Position the vehicle on a level surface.
Remove the fill plug.
Place a drain pan under the demand drive unit.
Remove the drain plug. Allow the fluid to drain completely.
Clean and reinstall the drain plug. Torque to specification.
Add the recommended fluid.
Reinstall the fill plug. Torque to specification.
Check for leaks. Dispose of used fluid properly.
73
MAINTENANCE
Transmission Oil
Always check and change the
transmission oil at the intervals outlined in
the Periodic Maintenance Chart
beginning on page 63. Maintain the
transmission oil level at the bottom of
the fill plug hole (1).
Refer to the Gearcase Specifications
Chart on page 72 for recommended
lubricants, capacities and torque
specifications. See page 111 for the part
numbers of Polaris products.
The transmission oil fill plug (2) is
located on the right side of the ATV
behind the footwell. The transmission
drain plug (3), is located on the bottom
left-hand side of the gearcase.
2
1
3
Oil Check
1.
2.
3.
4.
Remove the footwell (see page 82).
Remove the fill plug and check the oil level.
Reinstall the fill plug. Torque to specification.
Reinstall the footwell.
Oil Change
1. Remove the footwell (see page 82).
2. Remove the drain plug and drain the oil into a drain pan. Dispose
of properly.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug and add the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
74
Rear Gearcase Oil
MAINTENANCE
The rear gearcase has two
fill plugs. The rear fill
plug is located on the rear
of the gearcase and is not
easily accessible. The side
fill plug (1) is located on the
1
left side of the gearcase.
Use the side fill plug when
2
checking or changing oil.
Always check and change
the rear gearcase oil at the
intervals outlined in the
Periodic Maintenance Chart
beginning on page 63.
Maintain the oil level (2) even with the bottom of the side fill hole.
Refer to the Gearcase Specifications Chart on page 72 for
recommended lubricants, capacities and torque specifications. See
page 111 for the part numbers of Polaris products.
Oil Check
1. Position the vehicle on a level surface.
2. Remove the side fill plug and view the oil level through the fill
plug hole.
3. Add the recommended gearcase oil as needed.
4. Reinstall the fill plug. Torque to specification.
Oil Change
1. Place a drain pan beneath the drain and remove the drain plug.
Catch and discard used oil properly.
2. Clean and reinstall the drain plug with a new sealing washer.
Torque to specification.
3. Remove the side fill plug and add the recommended fluid.
4. Check the oil level. Maintain the oil level at the bottom of the fill
plug hole.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
75
MAINTENANCE
Engine Cooling System
To ensure that the coolant maintains its ability to protect the engine,
Polaris recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.
Polaris recommends the use of Polaris Premium 60/40
anti-freeze/coolant or a 50/50 mixture of high quality aluminum
compatible anti-freeze/coolant and distilled water. Polaris Premium
60/40 is already premixed and ready to use. Do not dilute with water.
See page 111 for the part numbers of Polaris products.
NOTE:
Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.
Any time the cooling system has been drained for maintenance or
repair, replace the coolant. If the recovery bottle has run dry, the level
in the radiator should be inspected. Add coolant as needed.
WARNING
Escaping steam can cause severe burns. Never remove the
pressure cap while the engine is warm or hot. Always allow the
engine to cool before removing the pressure cap.
76
MAINTENANCE
Engine Cooling System
Radiator Coolant Level
1.
2.
3.
4.
5.
6.
Remove the bolts securing the front rack. See illustration.
Remove the rack.
Remove the pressure cap (1).
Using a funnel, slowly add coolant through the radiator filler neck.
Reinstall the pressure cap.
Reinstall the front rack.
NOTE:
Use of a non-standard pressure cap will not allow the
recovery system to function properly. Contact your dealer for
the correct replacement part.
1
77
MAINTENANCE
Engine Cooling System
Coolant Level
The recovery bottle (1) is
located on the left side of the
machine. To access the
recovery bottle, remove the
left side panel as outlined on
page 82.
Maintain the coolant level
between the minimum and
maximum marks on the
bottle (when the fluid is
cool). Add coolant as
needed.
1
Cooling System Operation
The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the recovery bottle,
radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the recovery bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
NOTE:
78
Some coolant level drop on new machines is normal, as the
system is purging itself of trapped air. Observe coolant
levels and maintain as recommended by adding coolant to
the recovery bottle.
Steering Assembly
MAINTENANCE
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your Polaris
dealer for service before operating the vehicle.
Toe Alignment
WARNING
Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod
adjustments should be performed by an authorized Polaris dealer.
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ to 1/4″ (3-6 mm) toe out.
1. Set the handlebars in a
straight-ahead position.
NOTE:
The steering frog can
be used as an indicator
of whether the
handlebars are straight.
The frog should always
point straight back from
the steering post.
2
2. Place stands (1) in front of
the vehicle, perpendicular to
the rear tires. See
illustration.
3
3. Tie an elastic string around
the stands, making sure the
string just touches the side
surface of the rear tires on
each side of the vehicle and
goes around the stands in
front of the vehicle (2).
1
4. Measure the distance from
the string to the rim at the
front and rear of the front rim (3). Rear measurement should be
1/16″ - 1/8″ (1.5-3 mm) more than the front measurement.
NOTE:
If you discover improper alignment, see your Polaris dealer
for service.
79
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever toward the handlebar. These brakes are
self-adjusting.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
WARNING
Never store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury. After opening a bottle of brake fluid,
always discard any unused portion.
1. Always keep brake fluid at an adequate level (see page 30).
WARNING
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
NOTE:
80
Under normal operation, the diaphragm extends into the
reservoir as fluid level drops. If the fluid level is low and the
diaphragm is not extended, a leak is likely and the diaphragm
should be replaced. Always fill the reservoir as needed
whenever the cover is loosened or removed to ensure proper
diaphragm operation. Use Polaris DOT 4 brake fluid. Do not
overfill.
Brakes
MAINTENANCE
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear,
damage and looseness.
5. Check the security and surface
condition of the disc.
NOTE:
Pads should be changed
when worn to 3/64″ (1 mm).
Auxiliary Brake
3/64″ (1 mm)
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, the rear brake can be
activated by depressing the foot pedal on the inside of the right
footrest. The hydraulic auxiliary brake system requires no adjustment.
NOTE:
Since this is a rear brake only, it will not be as effective as
the all-wheel single lever system.
81
MAINTENANCE
Side Panel Removal
1. Remove the seat.
2. Grasp the rear of the side panel near the rear cab. With a firm
motion, pull the panel outward to disengage the side panel from the
grommet.
3. Pull the panel downward and rearward to remove it from the ATV.
4. Reinstall the side panel by reversing the removal procedure.
3
1
2
3
Footwell Removal
2
1. Remove the four screws (1)
on the bottom of the footwell.
2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets (2) securing the
footwell to the fenders.
3. Use a phillips screwdriver
and wrench to remove the
mudflap screws (3).
4. Remove the footwell.
3
1
82
Tires
MAINTENANCE
Refer to the specifications section beginning on page 112 for
recommended tire type, size and pressure.
WARNING
Operating your ATV with worn tires, improperly inflated tires,
non-standard tires or improperly installed tires will affect vehicle
handling and could cause an accident resulting in serious injury or
death.
Maintain proper tire pressure.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8″ (3 mm)
or less.
Tire Tread Depth
Always replace tires when tread
depth is worn to 1/8″ (3 mm) or less.
See illustration.
1/8I (3 mm)
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle
nut retention are critical component
operations. All service must be performed
by your authorized Polaris dealer.
Wheel Removal
1.
2.
3.
4.
5.
Stop the engine.
Place the transmission in PARK.
Lock the parking brake.
Loosen the wheel nuts slightly.
Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
83
MAINTENANCE
Tires
Wheel Installation
WARNING
Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death.
Always ensure that all nuts are torqued to specification. Do not
service axle nuts that have a cotter pin installed. See your
Polaris dealer.
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the wheel hub with the valve stem toward the
outside and the rotation arrows on the tire pointing toward forward
rotation.
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
90 ft. lbs.
(122 Nm)
Cast Aluminum
27 ft. lbs.
(37 Nm)
Steel
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.
84
Item
Specification
Lug Nut
90 ft. lbs. (122 Nm)
2-Piece Flange Nut
27 ft. lbs. (37 Nm)
Air Filter Service
MAINTENANCE
1
1. Remove the seat, release the
air box cover clips, and
2
remove the air box cover.
2. Loosen the clamp and remove
the filter.
3. Remove the fabric type
pre-filter (1) from the main
filter (2). Wash the pre-filter
in soapy water, then rinse and
3
let dry.
4. Reinstall the pre-filter over the
main filter. (Replace the main
filter if needed.)
5. Reinstall the filter into the air box and tighten the clamp. Do not
over tighten the clamp, as filter damage could occur.
6. Reinstall the air box cover and the seat.
Breather Filter/Hose
1. To access the breather filter (3), remove the left side panel as
outlined on page 82. The breather filter is on the hose that runs
between the engine and air box.
2. Remove the clamps and pull the filter out of the hoses.
NOTE:
It’s not necessary to remove the lower hose from the engine.
3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace if needed.
4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.
5. Reinstall the filter and secure the clamps.
NOTE:
The filter is effective with the arrow pointing in either
direction.
CAUTION
Operation of your vehicle without a breather filter can cause
engine damage. Always reinstall the breather filter after removing
for service.
85
MAINTENANCE
Lights
When servicing a halogen lamp, don’t touch the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that
will shorten the life of the lamp.
WARNING
Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal
operation. Wash the headlights frequently to maintain lighting
quality.
Hot components can cause serious burns to skin. Allow lamps to
cool before servicing.
Headlight Lamp Replacement
1. Remove the two screws on the lower front corners of the headlight
pod.
2. Remove the screw from the rear of the pod.
3. Lift the pod slightly while depressing the tabs at the rear of the
pod.
4. Lift the pod cover and disconnect the speedometer harnesses from
the speedometer.
5. Unplug the headlamp from the wiring harness. Be sure to pull on
the connector, not on the wiring.
6. Turn the lamp counterclockwise to remove it.
7. Apply dielectric grease to the socket and install the new lamp.
NOTE:
Make sure the tab on the lamp locates properly in the
housing.
8. Reassemble the pod.
86
Lights
MAINTENANCE
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
25 ft.
(7.6 m)
2″ (5 cm)
1. Position the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall. Place the transmission in
PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine. Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of
the headlight beam should be two inches (5 cm) below the mark on
the wall.
NOTE:
Include rider weight on the seat when measuring.
5. The adjustment knob is located on the right side of the headlight
pod. Adjust the beam to the desired position by turning the knob
either clockwise or counterclockwise.
87
MAINTENANCE
Lights
Low Beam Adjustment
1
The low beam can be
adjusted slightly upward or
downward.
1. Loosen the headlamp
mounting bolt (1).
2. Tilt the headlamp
upward or downward.
3. Tighten the bolt.
Headlight Housing Replacement
1. Remove the two screws on the lower front corners of the headlight
pod.
2. Lift the pod slightly while depressing the tabs at the rear of the
pod.
3. Lift the pod cover and disconnect the speedometer harnesses from
the speedometer.
4. Unplug the headlamp from the wiring harness.
5. Use a small screwdriver to remove the o-rings from the headlight
mounting tabs.
6. Pull the headlight housing up to release it from the locking tabs.
7. Lift the adjusting knob up to remove it from the locking tabs.
8. Carefully pull the assembly up and out of the pod.
9. Reverse the steps to install the new
housing and reassemble the pod.
NOTE:
The distance from the
headlamp parting line to the
end of the adjustment knob
stop is 5 1/8″ (13 cm).
10. Adjust the headlight aim by
turning the adjusting knob.
5 1/8″
(13 cm)
88
MAINTENANCE
Lights
Lower Headlamp Removal / Installation
1. Turn the back of the headlight harness (1) in
a clockwise direction.
2. Pull the harness assembly out from the
headlight assembly.
3. Remove the headlamp and install
1
the new headlamp.
4. Install the new headlamp and harness
assembly into the headlight assembly. Turn the
headlight harness counterclockwise to secure.
Taillight/Brakelight Lamp Replacement
1. Remove the taillight lens
cover mounting screws (1).
2. Remove the lens cover (2)
and gasket.
3. Remove the lamp (3).
4. Apply dielectric grease to the
socket and install the new
lamp.
5. Test the taillight/brakelight.
6. Reinstall the gasket and lens cover.
2
1
3
89
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Refer to the specifications section beginning on page 112 for the
recommended spark plug type and gap for your vehicle.
Spark Plug Torque Specification
Plug Condition
Torque
New Spark Plug
9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug
17-20 ft. lbs. (23-27 Nm)
Spark Plug Inspection
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. See page 91.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation, using the
recommended spark plug. Torque to specification.
90
Spark Plugs
MAINTENANCE
Spark Plug Inspection
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE:
The tip should not be flaky and white. A white insulator tip
indicates overheating, caused by use of an improper spark
plug or incorrect carburetion adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended oil, improper use of the choke, or incorrect
carburetion adjustments.
91
MAINTENANCE
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry land or at the very
least, to water below the footrests.
2. Check the air box for any water and
dry it if water is present. Filter
replacement is required if water
intrusion is evident.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Loosen the carburetor drain screw (1).
1
6. Turn the engine over several times
using the electric start.
7. Dry the spark plug and reinstall, 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.
NOTE:
92
If water has been ingested into the PVT, follow the procedure
on page 96 for drying out the PVT.
Recoil Housing
Always drain the recoil
housing (1) after operating
the vehicle in wet
conditions. Drain the
housing before storing the
vehicle.
MAINTENANCE
1
NOTE:
Make sure the
housing is
completely dry before
reinstalling the drain
screw.
NOTE:
Water will enter the recoil housing if the starter handle is
disengaged from the rope guide when under water.
1.
2.
3.
4.
5.
Stop the engine.
Place the transmission in gear.
Lock the parking brake.
Remove the drain screw on the bottom of the recoil housing.
Reinstall the drain screw.
NOTE:
Do not open the crankcase drain unless the engine has
ingested water. On 4-cycle engines, some engine oil will be
lost if the crankcase drain is opened.
93
MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.
Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.
Remove any combustible materials from the area. Wear eye
protection and leather work gloves. Do not stand behind or in
front of the vehicle while purging. Never run the engine in an
enclosed area. Exhaust contains poisonous carbon monoxide
gas.
Never go under the vehicle while it’s inclined.
1. Remove the arrestor clean-out
plug (1) from the bottom of the
muffler.
2. Place the transmission in PARK.
3. Start the engine.
2
4. Quickly squeeze and release the
1
throttle lever several times to
purge carbon from the system.
5. If carbon comes out of the exhaust,
cover or plug the exhaust outlet. Wear
protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while
repeating step 4.
7. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot (30 cm) higher than the front. Block the
wheels.
8. Place the transmission in PARK. Lock the parking brake. Repeat
steps 4-6 until no more particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor plug and remove the exhaust outlet cover or
plug.
94
MAINTENANCE
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of pinch applied to the
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt pinch.
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 (11 KPH), due to the
system’s dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 KPH) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1200 - 1400 RPM. However, in high
range at 3 MPH (5 KPH), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed
to prevent belt slip. Belt slip is responsible for creating the excessive
heat that destroys belts and causes outer clutch covers to fail.
By switching to low range while operating at low ground speeds, the
air temperature in the clutch cover is reduced by almost 160 degrees.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).
When To Use Low Range and High Range
Condition
Range to Use
Operating at speeds less than 7 MPH (11 km/h)
Low
Towing heavy loads
Low
Operating in rough terrain (swamps, mountains, etc.)
Low
Operating at speeds greater than 7 MPH (11 km/h)
High
95
MAINTENANCE
PVT 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 PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.
PVT Drying
There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Replace the
drain plug.
2. Start the engine and shift the transmission into neutral. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.
96
Battery
MAINTENANCE
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
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. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes and get prompt medical
attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near
batteries. KEEP OUT OF REACH OF CHILDREN.
97
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.
Battery Removal
1. Disconnect the hold-down strap holding the battery in position, and
remove battery cover.
2. Remove the battery vent tube.
3. Disconnect the black (negative) battery cable first.
4. Disconnect the red (positive) battery cable last.
5. Lift the battery out of the ATV. Be careful not to tip the battery
sideways, which could 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 vehicle.
98
Battery
MAINTENANCE
Battery Installation
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Install the battery vent tube.
NOTE:
The vent tube must be free of obstructions and securely
installed. Route the tube away from the frame and vehicle
body to prevent contact with electrolyte.
WARNING
Battery gases could accumulate in an improperly installed vent
tube and cause an explosion, resulting in serious injury or death.
Always ensure that the vent tube is free of obstructions and is
securely installed as recommended.
4.
5.
6.
7.
8.
Coat the terminals with dielectric grease or petroleum jelly.
Connect and tighten the red (positive) cable first.
Connect and tighten the black (negative) cable last.
Reinstall the battery cover. Secure the hold-down strap.
Verify that cables are properly routed.
NOTE:
Cables should be safely tucked away at the front and rear of
the battery.
99
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE:
Power plug leads may need to be bent down so that the
battery cover can be installed.
NOTE:
Battery charge can be maintained by using a Polaris Battery
Tender charger or by charging about once a month to make
up for normal self-discharge. Battery Tender can be left
connected during the storage period, and will automatically
charge the battery if the voltage drops below a
pre-determined point.
Replenishing Battery Fluid
A poorly maintained battery will
deteriorate rapidly. Check the
battery fluid level often. The fluid
level should be kept between the
upper and lower level marks (1).
To refill use only distilled water.
Tap water contains minerals that are
harmful to a battery.
100
1
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is
adjusted by rotating the adjuster (1)
either clockwise or
counterclockwise to increase or
decrease spring tension.
NOTE:
1
Accessory springs are
available through your
Polaris dealer.
Handlebars
The handlebars can be adjusted for rider preference.
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.
1. Remove the upper
headlight pod.
2. Loosen the four bolts (1).
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the gas
tank or any other part of the machine
when turned fully to the left or right.
4. Torque the front two bolts to 10-12 ft.
lbs. (14-17 Nm), then torque the rear
two bolts. A gap of up to 1/8” (3 mm)
will remain at the rear bolts.
1
101
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. Although this power cannot be regained, adjustments to
the carburetor and drive system can be made to allow more efficient
operation. Optional jets, available from your Polaris dealer, are
required for operation above 6,000 feet and temperatures below +40
degrees F. (4 degrees C.)
NOTE:
Continuous operation of the engine without proper jetting
when required can cause poor performance, overheating or
PVT or engine damage. See your Polaris dealer for more
information about jetting the ATV for conditions in your area.
NOTE:
Pilot screws are sealed with metal plugs and are serviceable
only by Polaris dealers.
Carburetor Idle
If the engine idle speed is not satisfactory, and
all other conditions are favorable, the carburetor
can be adjusted.
1. Start the engine and allow it to warm up for
approximately five minutes.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the screw in (clockwise) to raise RPM.
Turn the screw out (counterclockwise) to
lower RPM.
102
1
Throttle Cable Freeplay
MAINTENANCE
Adjust throttle cable freeplay at the handlebar.
1. Locate the throttle cable adjuster at
the handlebar.
2. Squeeze the end of the rubber boot
and slide it far enough to expose the
end of the inline cable adjuster.
3. Loosen the adjuster lock nut.
4. Rotate the boot to turn the adjuster
until 1/16″ to 1/8″ (1.5--3 mm) of
freeplay is achieved at the thumb
lever.
NOTE:
While adjusting freeplay, be
sure to flip the throttle lever
back and forth.
5. Tighten the lock nut.
6. Squeeze the end of the rubber boot
and slide it over the cable adjuster to
its original position.
1
3
2
Accessories
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights. See your Polaris dealer.
103
MAINTENANCE
Cleaning and Storage
See page 111 for the part numbers of Polaris products.
Washing the Vehicle
Keeping your ATV clean will not only improve its appearance but it
can also extend the life of various components.
CAUTION
High water pressure may damage ATV components. Polaris
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Do not allow these types of products to
come into contact with the vehicle.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional--type washing cloth, cleaning the upper body
first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
S Avoid the use of harsh cleaners, which can scratch the finish.
S Do not use a power washer to clean the vehicle.
S Do not use medium to heavy duty compounds on the finish.
S Always use clean cloths and pads.
104
Cleaning and Storage
MAINTENANCE
Washing the Vehicle
If a high pressure water system is used for cleaning (not
recommended), exercise extreme caution. The water may damage
components and could remove paint and decals. Avoid directing the
water stream at the following items:
S Wheel bearings
S Radiator
S Transmission seals
S Brakes
S Cab and body panels
S Labels and decals
NOTE:
If warning and safety labels are damaged, contact your
Polaris dealer for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
This vehicle has a factory-dulled finish. Do not polish this vehicle.
105
MAINTENANCE
Cleaning and Storage
Storage Tips
CAUTION
Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 104.
Stabilize the Fuel
1. Fill the fuel tank.
2. 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.
NOTE:
Carbon Clean removes water from fuel systems, stabilizes
fuel and removes carbon deposits from pistons, rings, valves
and exhaust systems.
3. Allow the engine to run for 15--20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.
4. Turn the fuel valve off.
5. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 70.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Drain the sediment tube.
Breather Filter
Inspect and clean or replace the breather filter.
Recoil Housing
Drain the recoil housing. See page 93.
106
Cleaning and Storage
MAINTENANCE
Storage Tips
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 63.
S Demand drive unit (front gearcase)
S Rear gearcase (if equipped)
S Transmission
S Brake fluid (change every two years and any time the fluid looks
dark or contaminated)
S Coolant (test strength/fill)
Fog the Engine
1. Support the front end of the machine so the engine is level or tilted
slightly rearward.
2. Remove the spark plug.
3. Pour 2-3 tablespoons (29-44 ml) of Premium 4 Synthetic 0W40
engine oil into the hole.
NOTE:
Use a section of small hose and a small plastic squeeze bottle
filled with the pre-measured amount of oil.
4. Reinstall the spark plug. Torque to specification.
5. Apply dielectric grease to the inside of the spark plug cap.
Reinstall the cap.
6. Turn the engine over several times using 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.
7. Treat the fuel system with Polaris Carbon Clean. See page 106.
8. If Polaris fuel system additive is not used, the fuel tank, fuel lines,
and carburetor should be completely drained of gasoline.
9. To eliminate any fuel remaining in the carburetor, run the engine
until it stops.
107
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate. Follow lubrication guidelines in the
Maintenance Section of the service or owner’s manual to completely
grease and lubricate the entire vehicle with Polaris Premium All
Season Grease.
Battery Storage
See page 100 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine Polaris cover.
NOTE:
108
Do not use plastic or coated materials. They do not allow
enough ventilation to prevent condensation, and may promote
corrosion and oxidation.
Cleaning and Storage
MAINTENANCE
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion,
preserve wheel life and ensure a ”like new” appearance for many years.
NOTE:
Chrome wheels exposed to road salt (or salt in the air in
coastal areas) are more susceptible to corrosion if not
properly cleaned. Clean chrome wheels more often if they’re
exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each
polished chrome wheel. Choose a product suitable for chrome
finishes. Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000--OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as
outlined above.
109
MAINTENANCE
Transporting the ATV
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in
PARK and lock the
parking brake.
3. Turn the fuel valve off.
Make sure the fuel caps,
oil cap and seat are
installed securely.
4. Always tie the frame of
the ATV to the
transporting unit securely
with suitable straps or
rope. Do not attach tie
straps to the front A-arm
bolt pockets.
110
POLARIS PRODUCTS
Part No.
Description
2870791
2871281
2871844
Engine Lubricant
Fogging Oil (12 oz. Aerosol)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)
2873602
2873603
2871653
2872276
2870465
2876251
Gearcase / Transmission Lubricants
Premium AGL Synthetic Gearcase Lubricant (qt.)
Premium AGL Synthetic Gearcase Lubricant (gal.)
Premium ATV Angle Drive Fluid (8 oz.)
Premium ATV Angle Drive Fluid (2.5 gal.)
Pump for Gallon Jug
Demand Drive LT Premium Fluid (8 oz.)
2871312
2871322
2871423
2871460
2871515
2871551
2871329
2872073
2872348
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Starter Drive Grease
Premium U-Joint Lube (3 oz.)
Premium U-Joint Lube (14 oz.)
Dielectric Grease (Nyogelt)
Chain Lube (6.25 oz. aerosol)
Chain Lube (16 oz. aerosol)
2871323
2871534
Coolant
60/40 Coolant (gal.)
60/40 Coolant (qt.)
2872889
2871326
2870652
2872189
2872893
2871956
2871076
Additives / Miscellaneous
Brake and Clutch Cleaner
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT4 Brake Fluid
Engine Degreaser
LOCTITE 565 Thread Sealant
Polaris Battery Tender Charger
111
SPECIFICATIONS
MV700
Gross Vehicle Weight
Dry Weight
Fuel Capacity, Front Tank
Fuel Capacity, Rear Tank
Towing Capacity
Front Rack Capacity
Rear Rack Capacity
Hitch Tongue Capacity
Winch Capacity
Overall Length
Overall Width
Overall Height
Wheelbase
Ground Clearance
Minimum Turning Radius
Engine Oil Capacity
Coolant Capacity
Demand Drive Fluid Capacity
Rear Gearcase Oil Capacity
Engine
Displacement
Bore x Stroke
Pilot Jet
Main Jet
Needle Jet
Jet Needle
Pilot Screw
Alternator Output
Compression Ratio
Starting System
Carburetor
Ignition System
Ignition Timing
Spark Plug / Gap
Lubrication System
Driving System Type
112
1900 lbs. (862 kg)
1170 lbs. (531 kg)
4.75 gal. (18 l)
4.0 gal. (15 l)
1500 lbs. (681 kg)
200 lbs. (91 kg)
400 lbs. (181 kg)
150 lbs. (68.1 kg) (Rear rack capacity and tongue
weight not to exceed 400 lbs./181 kg)
2500 lbs. (1134 kg)
95 in. (241 cm)
48 in. (122 cm)
59 in. (150 cm)
50.75 in. (129 cm)
10.5 in. (26.7 cm)
71.5 in. (181.6 cm) unloaded
2 qts. (1.9 l)
3.2 qts. (3 l)
9 oz. (265 ml)
10 oz. (300 ml)
EH068OLE017
683
80 x 68
45
157.5
P-6 (829)
4HB41-4
2 3/8
330 Watts @ 3000 rpm
9.78:1
Electric
BST 34mm Mikuni
CDI
13° BTDC @ 1200 RPM
RC7YC / .035 in. (0.9 mm)
Pressurized Wet Sump
4 Wheel Independent Shaft
SPECIFICATIONS
MV700
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front
Drive Ratio - Final
Tire Size/Pressure - Front
Tire Size/Pressure - Rear
Front Brake
Rear Brake
Parking Brake
Front Suspension
Rear Suspension
Shock Adjustment
Headlight
Taillights
Brake Light
Instrument Cluster
Side Lever (H/L/N/R/P)
7.49/1
5.11/1
3.05/1
3.82/1
3.10/1
25 x 8 - 12 / 5 psi (34.5 KPa)
25 x 8 - 12 / 5 psi (34.5 KPa)
Single-Control Hydraulic Disc
Single-Control Hydraulic Disc
Hydraulic lock, all wheel
MacPherson Strut with 8.2” (21 cm) of travel
Progressive Rate with 8.5” (21.6 cm) of travel
Rear Spring Preload Adjust
2 Single Beam on Grill (27 w)
8.26 w
26.9 w
LCD
Jetting Chart
Altitude
AMBIENT
TEMPERATURE
Below 40° F
Below 5° C
+40° F and above
+5° C and above
Meters
(Feet)
0-1800
(0-6000)
162.5
157.5
1800-3700
(6000-12000)
155
150
Clutching Chart
Altitude
Meters
(Feet)
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
0-1800
(0-6000)
20-56
PN 5631215
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS 41-37
PN 5132751
1800-3700
(6000-12000)
20-54
PN 5631214
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS 41-37
PN 5132751
*EBS models require no helix / spring adjustment
113
TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause
Solution
Driving the ATV onto a
pickup or tall trailer in
high range.
Shift transmission to low range during loading of the ATV
to prevent belt burning.
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 57.
Driving at low RPM or
Drive at a higher speed or use low range more frequently.
low ground speed (at
The use of low range is highly recommended for cooler
approximately 3-7 MPH). PVT operating temperatures and longer component life.
Insufficient warm-up of
Warm the engine at least 5 minutes. With the transmission
ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in
bient temperatures.
short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow and easy clutch engagement.
Use the throttle quickly and effectively for efficient engagement.
Towing/pushing at low
RPM/low ground speed.
Use low range only.
Utility use/plowing snow,
dirt, etc.
Use low range only.
Stuck in mud or snow.
Shift the transmission to low range, and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large objects from a stopped position.
Shift the transmission to low range, and 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
Shift the transmission to neutral. Using the throttle, vary
or snow ingestion into the the engine RPM from idle to full throttle. Repeat several
PVT system.
times as required. During this procedure, the throttle
should not be held at the full position for more than 10
seconds. Clutch seals should be inspected for damage if
repeated leaking occurs.
Clutch malfunction.
Contact your Polaris dealer for inspection of clutch components.
Poor engine performance. Check for fouled plugs or foreign material in gas tank,
fuel lines, or carburetor. Contact your dealer for service.
114
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Doesn’t Turn Over
Possible Cause
Solution
Tripped circuit breaker
Reset the breaker
Low battery voltage
Recharge battery to 12.5 VDC
Loose battery connections
Check all connections and tighten
Loose solenoid connections
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Solution
Out of fuel
Refuel or switch tanks
Clogged fuel valve or filter
Inspect and clean or replace
Water is present in fuel
Drain the fuel system and refuel
Fuel valve is turned off
Turn the fuel valve on
Old or non-recommended fuel
Replace with new fuel
Fouled or defective spark plug(s)
Inspect plug(s), replace if necessary
No spark to spark plug
Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel
Immediately see your Polaris dealer
Overuse of choke
Inspect, clean and/or replace spark plugs
Clogged fuel filter
Replace the filter
Low battery voltage
Recharge battery to 12.5 VDC
Mechanical failure
See your Polaris dealer
Engine Pings or Knocks
Possible Cause
Solution
Poor quality or low octane fuel
Replace with recommended fuel
Incorrect ignition timing
See your Polaris dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
115
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
Engine Runs Irregularly, Stalls or Misfires
Possible Weak Spark 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 to 12.5 VDC
Kinked or plugged fuel vent line
Inspect and replace
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your Polaris dealer
Electronic Throttle Control malfunction
See your Polaris dealer
Other mechanical failure
See your Polaris dealer
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
116
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Solution
Out of fuel
Refuel or switch tanks
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 connections
Check all connections and tighten
Low battery voltage
Recharge battery to 12.5 VDC
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your Polaris dealer
Electronic Throttle Control malfunction
See your Polaris dealer
Other mechanical failure
See your Polaris dealer
Overheated engine
Clean radiator screen and core
Clean engine exterior
See your Polaris dealer
Engine Overheating
Possible Cause
Solution
Debris lodged in screen
Remove and clean the screen. Pull on the
top portion of the screen, then remove the
lower portion.
Plugged Radiator
Use a garden hose to flush any debris
from the radiator fins. NOTE: High pressure washers can deform the radiator fins
and reduce cooling efficiency.
117
WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against
defects in material or workmanship. Polaris also gives a one year limited warranty on the
final drive chain for failure due to defects. This warranty covers the parts and labor
charges for repair or replacement of defective parts which are covered by this warranty.
This warranty begins on the date of purchase. This warranty is transferable to another
consumer during the warranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set--up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set--up will
void your warranty coverage.
118
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. This warranty also does not cover any ATV that
has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the ATV due to fire, explosions or any other cause beyond Polaris’
control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the ATV. The exclusive remedy for breach of this warranty shall
be, at Polaris’ exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY
OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some
states do not permit the exclusion or limitation of incidental or consequential damages or
implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.
119
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.
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.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of Polaris engine oil for your ATV.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
SPARK ARRESTOR
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and
when maintenance and installation are in accordance with Polaris recommendations.
120
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.
This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.
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. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
121
WARRANTY
Exported Vehicles
How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100
122
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited
warranty is in addition to the Polaris standard limited warranty for this vehicle.
Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the
time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in
materials and workmanship that may keep it from meeting these requirements.
The emissions warranty period for this vehicle begins on the date the vehicle is delivered
to the original retail purchaser and ends 30 months (2.5 years) after that date, or after
5000 km (3100 miles), whichever comes first.
This emission--related warranty covers components whose failure would increase an
engine’s emissions, including electronic controls, fuel injection, exhaust--gas recirculation, aftertreatment, or any other system utilized in this vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or the
standard warranty is the responsibility of the owner; including the parts, labor and other
costs associated with recommended maintenance.
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.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD
DESCRIBED HEREIN. POLARIS 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 if it is inconsistent
with the controlling state law.
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 any engine that has been used in racing competition. This
limited warranty also does not cover physical damage, corrosion or defects caused by
fire, explosions or other similar causes beyond the control of Polaris.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the Polaris Warranty Department at 1--763--417--8650.
123
MAINTENANCE RECORD
DATE
124
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE RECORD
DATE
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
125
MAINTENANCE RECORD
DATE
126
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
INDEX
A
E
Accessories . . . . . . . . . . . . . . . . . . 103
Age Restrictions . . . . . . . . . . . . . . . . 6
Air Filter Service . . . . . . . . . . . . . . . 85
All Wheel Drive . . . . . . . . . . . . . . . 37
Automatic Transmission . . . . . . . . . 34
Auxiliary Brake . . . . . . . . . . . . . . . 81
AWD . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Switches . . . . . . . . . . . . . 27
Electromagnetic Interference . . . . . . 62
Emission Control Systems . . . . . . . 62
Engaging All-Wheel Drive . . . . . . . 37
Engine Break-in . . . . . . . . . . . . . . . 45
Engine Cooling System . . . . . . . 76-78
Engine Stop Switch . . . . . . . . . . . . 27
Equipment Modifications . . . . . . . . 10
Exhaust Emission Control System . 62
B
Battery . . . . . . . . . . . . . . . . . . . 97-100
Battery Fluid . . . . . . . . . . . . . . . . . 100
Battery Installation . . . . . . . . . . . . . 99
Battery Removal . . . . . . . . . . . . . . . 98
Battery Storage . . . . . . . . . . . 100, 108
Belt Life . . . . . . . . . . . . . . . . . . . . . 34
Brake Fluid . . . . . . . . . . . . . . . . 30, 32
Brake Lever . . . . . . . . . . . . . . . . . . 29
Brake, Auxiliary . . . . . . . . . . . . . . . 32
Brakelight . . . . . . . . . . . . . . . . . . . . 89
Brakes . . . . . . . . . . . . . . . . . . . . . 80-81
Break-In Period . . . . . . . . . . . . . . . . 45
Breather Filter . . . . . . . . . . . . . . . . . 85
C
Camber and Caster . . . . . . . . . . . . 101
Carburetor . . . . . . . . . . . . . . . . . . . 102
Choke . . . . . . . . . . . . . . . . . . . . . . . 33
Chrome Wheel Care . . . . . . . . . . . 109
Cleaning . . . . . . . . . . . . . . . . . 104-109
Clutching Chart . . . . . . . . . . . . . . . 113
Cold Weather Operation . . . . . . . . . 48
Coolant Level . . . . . . . . . . . . . . . . . 78
Cooling System . . . . . . . . . . . . . 76-78
Cooling System Operation . . . . . . . 78
Crankcase Emission Control System 62
D
Demand Drive Fluid . . . . . . . . . . . . 73
Diagnostic Mode . . . . . . . . . . . . . 41-43
Drivetrain Break-in . . . . . . . . . . . . . 45
Driving Downhill . . . . . . . . . . . . . . 56
Driving in Reverse . . . . . . . . . . . . . 60
Driving on a Hillside . . . . . . . . . . . . 55
Driving on Slippery Surfaces . . . . . 53
Driving Procedures . . . . . . . . . . . . . 51
Driving Through Water . . . . . . . . . . 58
Driving Uphill . . . . . . . . . . . . . . . . 54
F
Footwell Removal . . . . . . . . . . . . . .
Front Gearcase Fluid . . . . . . . . . . . .
Front Wheel Hub Tightening . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . .
Fuel Requirements . . . . . . . . . . . . .
Fuel Safety . . . . . . . . . . . . . . . . . . .
Fuel Tanks . . . . . . . . . . . . . . . . . . .
Fuel Valve . . . . . . . . . . . . . . . . . . . .
82
73
83
33
33
44
33
33
G
Gear Selector . . . . . . . . . . . . . . . . . . 34
Gearcase Specification Chart . . . . . . 72
H
Handlebars . . . . . . . . . . . . . . . . . . 101
Hauling Cargo . . . . . . . . . . . . . . . 49-50
Headlamp, Lower . . . . . . . . . . . . . . 89
Headlight Housing Replacement . . . 88
Headlight Lamp Replacement . . . . . 86
High Beam Adjustment . . . . . . . . . . 87
High Range . . . . . . . . . . . . . . . . . . . 95
Hour Meter . . . . . . . . . . . . . . . . . . . 40
I
Idle RPM . . . . . . . . . . . . . . . . . . . 102
Ignition Switch . . . . . . . . . . . . . . . . 27
Infrared Light Switch . . . . . . . . . . . 27
Instrument Cluster . . . . . . . . . . . . 38-43
J
Jetting Chart . . . . . . . . . . . . . . . . . 113
K
K-Turn . . . . . . . . . . . . . . . . . . . . . . 57
127
INDEX
L
S
Light Switches . . . . . . . . . . . . . . . . 29
Lights . . . . . . . . . . . . . . . . . . . . . 86-89
Locking the Parking Brake . . . . . . . 31
Low Beam Adjustment . . . . . . . . . . 88
Low Range . . . . . . . . . . . . . . . . . . . 95
Lower Headlamp . . . . . . . . . . . . . . 89
Lubrication Guide . . . . . . . . . . . . . . 68
Safe Riding Gear . . . . . . . . . . . . . . . 26
Safety Training . . . . . . . . . . . . . . . . . 6
Severe Use . . . . . . . . . . . . . . . . . . . 63
Side Panel Removal . . . . . . . . . . . . 82
Sidehilling . . . . . . . . . . . . . . . . . . . 55
Spark Arrestor . . . . . . . . . . . . . . . . . 94
Spark Plug Inspection . . . . . . . . . 90-91
Spark Plug Recommendations . . . . 90
Spark Plugs . . . . . . . . . . . . . . . . . 90-91
Specifications . . . . . . . . . . . . . 112-113
Starting the Engine . . . . . . . . . . . 47-48
Steering Assembly . . . . . . . . . . . . . 79
Stop Switch . . . . . . . . . . . . . . . . . . . 27
Storage . . . . . . . . . . . . . . . . . . 104-109
Storage Tips . . . . . . . . . . . . . . 106-108
Switches . . . . . . . . . . . . . . . . . . . . . 27
Switch, Light . . . . . . . . . . . . . . . . . 29
M
Maintenance Chart . . . . . . . . . . . 63-67
Maintenance Record . . . . . . . . 124-126
Making Turns . . . . . . . . . . . . . . . . . 52
Master Cylinder . . . . . . . . . . . . . . . 30
Mode/Reverse Override Switch . . . 27
N
Noise Emission Control System . . . 62
O
Odometer . . . . . . . . . . . . . . . . . . . . 40
Oil Change . . . . . . . . . . . . . . . . . . . 71
Oil Check . . . . . . . . . . . . . . . . . . . . 70
Oil Filter Change . . . . . . . . . . . . . . 71
Operator Safety . . . . . . . . . . . . . . . 6-25
P
Parking Brake . . . . . . . . . . . . . . . . . 31
Parking on an Incline . . . . . . . . . . . 61
Periodic Maintenance Chart . . . . 63-67
Polaris Products . . . . . . . . . . . . . . 111
Pre-Ride Inspection . . . . . . . . . . . . . 46
Premium 4 Synthetic Lubricant . . . . 69
PVT Break-in . . . . . . . . . . . . . . . . . 45
PVT Drying . . . . . . . . . . . . . . . . . . 96
PVT System . . . . . . . . . . . . . . . . 95-96
R
Radiator Coolant Level . . . . . . . . . 77
Rear Gearcase Oil . . . . . . . . . . . . . . 75
Rear Spring . . . . . . . . . . . . . . . . . . 101
Recoil Housing . . . . . . . . . . . . . . . . 93
Recoil Starter . . . . . . . . . . . . . . . . . 35
Reverse Override Switch . . . . . . . . . 27
Rider Information Center . . . . . . 39-43
Run-Flat Tires . . . . . . . . . . . . . . . . . 36
128
T
Tachometer . . . . . . . . . . . . . . . . . . . 40
Taillight . . . . . . . . . . . . . . . . . . . . . . 89
Throttle Cable Freeplay . . . . . . . . . 103
Throttle Lever . . . . . . . . . . . . . . . . . 28
Tires . . . . . . . . . . . . . . . . . . . . . . 83-84
Tires, Run-Flat . . . . . . . . . . . . . . . . 36
Toe Alignment . . . . . . . . . . . . . . . . 79
Transmission Oil . . . . . . . . . . . . . . . 74
Transporting the ATV . . . . . . . . . . 110
Trip Meter . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting . . . . . . . . . . . 114-117
Turning Around on a Hill . . . . . . . . 57
V
Vehicle Identification Numbers . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 92
W
Warranty . . . . . . . . . . . . . . . . . 118-121
Washing the Vehicle . . . . . . . . . . . 104
Wheel Installation . . . . . . . . . . . . . . 84
Wheel Nut Torque Specifications . . 84
Wheel Removal . . . . . . . . . . . . . . . 83
Winch Switch . . . . . . . . . . . . . . . . . 27
Winches . . . . . . . . . . . . . . . . . . . . . 36