Polaris Sportsman 9920364 User's Manual

03
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be
attached to the owner's manual on the next page. If you cannot
locate this card, or if it has been removed, please call 1-800-3423764 for assistance.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• 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
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2006 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. 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 Sportsman 500 EFI Owner’s Manual
P/N 9920364
2
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Emission Control Systems . . . . . . . . . . . . . . . 71
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 127
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 128
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 136
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3
4
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Engine Serial Number
####
VIN
Key Number
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
5
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any of
the decals depicted in this manual differ from the decals on your ATV,
always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY
or DEATH
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A
REPLACEMENT.
+
6
Safety Decals and Locations
Discretionary
Warning
SAFETY
Tire Pressure/Load
Warning
+
+
Discretionary Warning
WARNING
• Never operate this ATV on HILLS steeper than 25 degrees
25°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes
gradually.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.
• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of
control, never activate override button with open throttle.
• When this ATV is not in operation, or unattended, place shift in the park position.
Tire Pressure/Load Warning
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING
MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered, carried as low as possible, and
firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is
best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner's Manual for more detailed loading information
7
SAFETY
Safety Decals and Locations
Rack
Warning
Age 16 Warning
Rack
Warning
+
+
+
+
+
“No Passenger”
Warning
Clutch Cover
Warning
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this ATV if you are under age 16.
8
Safety Decals and Locations
SAFETY
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
Rack Warning, Front and Rear
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
Reverse Override Warning
WARNING
Pushing reverse override button may cause sudden increases in power and
traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in AWD. See Owner's Manual.
All Wheel Drive Switch
Do not push switch to engage AWD if the rear wheels are spinning. This may
cause severe drive shaft and clutch damage. See your Owner's Manual.
Hitch Capacity Label
TRAILER MAX WEIGHT:
1225 LBS. (557 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)
9
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Eye Protection
Helmet
Long
Sleeves
Gloves
Long Pants
Boots
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
051039
distinguishing number of the country which has
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
10
Safe Riding Gear
SAFETY
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
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.
11
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This vehicle
handles differently than other vehicles, such as motorcycles and cars. A
collision or rollover can occur quickly, even during routine maneuvers like
turning, or driving on hills or over obstacles, if you fail to take proper
precautions.
Read 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.
12
Operator Safety
SAFETY
Safety Training
ATV safety training is a top priority for Polaris. When you purchased
your new ATV, your dealer instructed you on the authorized ATV
RiderCoursesm available to you and your eligible family members. This
training is included in the purchase price of your ATV. Polaris strongly
encourages you and your 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.
13
SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
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.
14
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.
• Read this manual and all labels carefully, and follow the operating
procedures described.
• 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.
• Never allow anyone under 16 years of age to operate this ATV.
• 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.
• Always avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets.
• Never operate an ATV on a public street, road or highway, including a
dirt or gravel road.
• Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield), gloves,
boots, a long-sleeved shirt or jacket, and long pants.
• Never consume alcohol or drugs before or while operating an ATV.
• Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
• Never attempt wheelies, jumps or other stunts.
• 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.
• Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
15
SAFETY
Operator Safety
• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.
• Never operate on excessively rough, slippery, or loose terrain.
• Always follow proper turning procedures as described in this manual.
Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
• Always have the ATV inspected by an authorized Polaris dealer if it's
been involved in an accident.
• Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills. Check the terrain
carefully before ascending a hill. Never climb hills with excessively
slippery or loose surfaces. Shift your weight uphill. Never open the
throttle suddenly or make sudden gear changes. Never go over the top
of a hill at high speed.
• 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 uphill. 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. Drive straight downhill.
• Always follow proper procedures for crossing the side of a hill. Avoid
hills with excessively slippery or loose surfaces. Shift your weight
uphill. Never attempt to turn the ATV around on any hill until you've
mastered (on level ground) the turning technique outlined in this
manual. Avoid crossing the side of a steep hill when possible.
• 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.
16
Operator Safety
SAFETY
• 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.
• 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.
• 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.
• Wet brakes may have reduced stopping ability. Test the brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
• Always check for obstacles or people behind the ATV before operating in reverse. When it's safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
• Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
• Never modify an ATV through improper installation or use of accessories.
• Never exceed the stated load capacity for your ATV. 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.
17
SAFETY
Operator Safety
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 1-800-3423764.
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: 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.
18
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the
operator does not know how to operate the ATV
properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should
complete the ATV RiderCoursesm offered by
Polaris through the SVIA. 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.
19
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 adversely
affect the handling of the ATV and could result in
loss of control, accident, and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it's
unavoidable, travel slowly and avoid sudden turns or stops.
20
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any public street,
road or highway, including dirt and gravel roads.
In many states it's illegal to operate ATVs on
public streets, roads and highways.
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, longsleeved shirt or jacket, and long pants.
21
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 causing severe
injury or death.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that's
proper for the terrain, visibility and operating
conditions, and your experience.
22
SAFETY
Operator 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.
23
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 contact 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.
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra caution when
operating on excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively rough,
slippery or loose terrain could cause
loss of traction or loss of control,
which could result in an accident or
overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain until you've
learned and practiced the skills necessary to control the ATV on such terrain.
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.
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never operate on hills too steep for the ATV or
for your abilities. Never operate the ATV on hills
steeper than 25 degrees.
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.
If your ATV is equipped with Active Descent Control, always engage AWD
before ascending a hill. See page 45.
Always check the terrain carefully before ascending any hill.
Never operate the ATV on hills steeper than 25 degrees.
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.
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill improperly.
WHAT CAN HAPPEN
Improperly descending a hill could
cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for
traveling down hills as described in
the owner's manual. NOTE: A special
technique is required when braking
while traveling downhill. See page 65.
Always descend a hill with the transmission in forward gear. Do not descend
a hill with the transmission in neutral. If your ATV is equipped with Active
Descent Control, always engage AWD before descending a hill. See page
45.
Always check the terrain carefully before descending a hill.
Shift your weight rearward.
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.
WARNING
POTENTIAL HAZARD
Improperly crossing hills and turning on hills.
WHAT CAN HAPPEN
Improperly crossing or turning on 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 66. 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.
27
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly
dismounting while climbing a hill.
WHAT CAN HAPPEN
The vehicle could overturn.
HOW TO AVOID THE HAZARD
Maintain steady speed when climbing a hill.
If your ATV is equipped with Active Descent
Control, always engage AWD before ascending
a hill. See page 45.
If all forward speed is lost:
Keep your weight uphill.
Apply the brakes.
Lock the parking brake when fully stopped.
If the ATV begins rolling backwards:
Keep weight uphill.
Never apply engine power.
Never apply the rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the 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 66.
28
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.
29
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or
fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction
and loss of control, which could lead to
an accident or overturn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep
or fast-flowing water. If it's unavoidable
to enter water that exceeds the
recommended maximum depth (see
page 67), 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
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.
30
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires, 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 in the owner's manual.
Always maintain proper tire pressure as described in the owner's manual and
on safety decals.
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.
31
SAFETY
Operator Safety
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.
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.
32
SAFETY
Operator Safety
WARNING
Operating a damaged ATV can result in an accident with serious injury or
death. After any overturn or accident, have a qualified service dealer inspect
the entire machine 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.
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the
exhaust system. Use caution when traveling through tall grass, especially dry
grass.
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle
resulting in serious injury or death. Always remove the ignition key when the
vehicle is not in use.
33
FEATURES AND CONTROLS
Switches
Headlight
Switch
Mode/Reverse
Override
Switch
Worklight
Switch
(if equipped)
Main Key Switch
Engine
Stop Switch
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.
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system.To gain
additional power while backing, depress the override switch.
NOTE: The override switch also allows activation of All Wheel Drive in
reverse, if the AWD switch is on. This switch is also used to toggle
through the modes of the rider information center. See page 46.
34
Switches
FEATURES AND CONTROLS
Engine Stop Switch
Move the stop switch either left
or right to the OFF position to
stop the engine quickly. The
engine will not start or run when
the switch is off.
OFF
RUN
OFF
NOTE: Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 57 for starting procedures.
Worklight Switch
Use the worklight switch (if equipped) to turn the worklight on or off.
The worklight is located at the rear of the vehicle. Turn the light on
while loading and unloading cargo in low light situations. Turn the
worklight off when driving.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam.
NOTE: The lights won't work unless the key is in the ON position and the
engine stop switch is 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.
35
FEATURES AND CONTROLS
Throttle Lever
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.
Engine speed and vehicle movement are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.
This ATV is equipped with Polaris
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
Modifications to the ETC could result in failure to perform as designed, which
could result in severe injury or death. Do not attempt to modify the ETC
system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is properly installed to the ETC.
36
Brake Lever
FEATURES AND CONTROLS
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These 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.
37
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
Check the brake fluid in the master
cylinder before each ride. The
fluid level can be seen through an
indicator window on the top of the
master cylinder. This eye will
appear dark when the fluid level is
full. When fluid is low, the eye
will be clear.
NOTE: When checking the fluid
level, the ATV must be on
level ground with the handlebars straight.
Master Cylinder
Indicator
Window
If the fluid level is low add DOT 4 brake fluid only. See page 127 for the
part numbers of Polaris products.
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.
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.
38
Parking Brake
FEATURES AND 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. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
Important Safeguards
• The parking brake may relax if left on for a long period of time.
Always block the wheels to prevent rolling.
• Always block the wheels on the downhill side of the ATV if leaving it
parked on a hill. Another option is to park the ATV in a sidehill position.
• Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
39
FEATURES AND CONTROLS
Auxiliary Foot Brake
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, use the auxiliary foot
brake.
NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel
single lever system.
WARNING
Aggressively applying the auxiliary brake when backing down a hill may
cause rear tipover, which could result in serious injury or death. Never back
down a hill.
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.
The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.
Auxiliary Foot Brake
NOTE: If the rear wheels slide while
using the auxiliary brake,
reduce brake pedal pressure
to brake the rear wheels without skidding.
Brake Fluid Level
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located near the auxiliary brake. Maintain the fluid level
between the maximum and minimum marks.
40
Fuel Tank Cap
FEATURES AND CONTROLS
Remove the fuel tank cap to
add fuel to the fuel tank. Use
either leaded or unleaded gasoline with a minimum pump
octane number of 87=(R+ M/2)
octane. Do not use E-85 fuel.
Fuel
Tank
Cap
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after
every 200 hours of operation
and any time the fuel becomes
contaminated with dirt or
debris. Do not attempt to clean
the fuel filter.
41
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear
selector is located on the
right side of the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
Whenever the ATV is left
unattended, always place
the transmission in PARK
and lock the parking brake.
Gear
Selector
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.
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.
42
Recoil Starter
FEATURES AND CONTROLS
If the battery is too weak to start
the engine, use the recoil starter.
Follow the starting procedures on
page 57, cranking the engine with
the recoil starter instead of the
main key switch.
1. Grasp the recoil starter rope
handle tightly.
2. Pull slowly so you can feel
the engine strokes.
Handle
Recoil Starter
NOTE: The rope will be harder to pull when the engine is on a compression
stroke. When a compression stroke is found, continue pulling the rope
just until the engine rolls past the stroke, then stop pulling immediately.
3. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
4. Repeat all steps until the engine starts.
5. Make sure the handle is fully seated on the housing.
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.
43
FEATURES AND CONTROLS
All Wheel Drive (AWD) System
The All Wheel Drive system is
controlled by the AWD switch.
When the switch is on 2X4, the
ATV is in two-wheel drive at all
times. When the switch is on
AWD, the ATV is in all wheel
AWD
drive and the AWD indicator light
Switch
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 34.
There is no limit to the length of time the vehicle may remain in AWD.
Engaging 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.
44
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system (if equipped) allows engine braking to all four wheels
when the vehicle descends a hill or incline. If your ATV is equipped
with Active Descent Control, always engage AWD before ascending or
descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the following conditions occur:
• The AWD switch must be in the AWD position
• Vehicle speed must be 15 mph (24 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the following conditions occur:
• The AWD switch is moved to the 2X4 position
• Vehicle speed exceeds 15 mph (24 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
45
FEATURES AND CONTROLS
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 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 34 for additional information.
Speedometer
Needle
Speedometer
Rider
Information
Center
NOTE: In addition to showing vehicle speed, the speedometer needle flashes
when a warning condition exists.
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.
46
FEATURES AND CONTROLS
Instrument Cluster
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 electronic speedometer. If this occurs, take the ATV to your Polaris
dealer for proper diagnosis.
1. Gear Indicator - This
6
3
4
5
7
indicator displays gear
shifter position:
8
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
2
P = Park
2. AWD Indicator - This
9
indicator illuminates
when the AWD switch
1
is in the AWD position.
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 operating at an RPM too low to keep the battery
charged. It may also occur when the engine 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/Clock
7. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.
8. Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also
appears if an EFI-related fault occurs. Do not operate the ATV if
this warning appears. Serious engine damage could result.
9. Mode Indicator
47
FEATURES AND CONTROLS
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 34.
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: Small fluctuations in the RPM from day to day may be normal because
of changes in humidity, temperature and elevation.
Clock Mode
The clock displays time in a 12-hour format. To reset the clock, see page
49.
48
FEATURES AND CONTROLS
Instrument Cluster
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 key 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 key 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 key switch on.
Release the switch as soon as the display is activated.
5. Use the mode button to toggle through the diagnostic screens.
Clock Screen
To reset the clock:
1. Enter the diagnostic mode.
2. Toggle to the clock screen.
3. Press and hold the mode button until the hour display 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.
5. When the desired hour is displayed, wait approximately four seconds, until the minute display flashes.
6. When the display stops flashing, the mode has been set.
7. Use the same procedure to reset the minutes.
49
FEATURES AND CONTROLS
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 51.
NOTE: The service interval is programmed at 50 hours at the factory.
50
FEATURES AND CONTROLS
Instrument Cluster
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.
51
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Downloading Codes
The EFI diagnostic mode is for informational purposes only. Please see
your Polaris dealer for all major repairs.
See page 53 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI
module.
1. Place the transmission in
PARK. Stop the engine.
Turn the key switch to the
ON position.
2. Turn the key switch off and
on three times in less than
five seconds. The word
“WAIt” will appear on the
screen.
3. The Check Engine icon will blink once, pause, then blink twice
(blink code 12) to begin the diagnostic sequence. The EFI module is
now searching for blink codes. If a code exists, the Check Engine
icon will flash the code.
4. Count the number of times the Check Engine icon flashes.
Example: For the two blink codes 42 and 36, the Check Engine icon will
flash 4 times, pause, then flash 2 times (code 42), then pause longer,
blink 3 times, pause, and blink 6 times (code 36).
5. A code 61 will signal the end of the sequence. If no blink codes are
found, only codes 12 and 61 will appear during the sequence.
NOTE: The word “WAIt” will remain on the screen through this entire process.
52
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Downloading Codes
Blink
Code
Failure Description
12
BEGIN SEQUENCE
45
Barometric Pressure/Manifold Air Pressure Sensor Low
46
Barometric Pressure/Manifold Air Pressure Sensor High
41
Air Temp Sensor Low Voltage
41
Air Temp Sensor High Voltage
42
Engine Coolant Temp Low Voltage
42
Engine Coolant Temp High Voltage
22
Throttle Position Sensor Low
22
Throttle Position Sensor High
51
Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground
51
Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery
52
Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground
52
Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery
56
Fuel Pump: Open Load/Short-to-Ground
56
Fuel Pump: Shorted Load/Short-to-Battery
44
Crank Position Sensor Circuit Fault
36
Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground
36
Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery
37
Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground
37
Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery
31
System Voltage Low
31
System Voltage High
55
MIL Circuit: Open Load/Short-to-Ground
55
MIL Circuit: Shorted Load/Short-to-Battery
58
Fan Circuit: Open Load/Short-to-Ground
58
Fan Circuit: Shorted Load/Short-to-Battery
47
IAC Stepper Motor: Open Load
47
IAC Stepper Motor: Short-to-Ground
61
END SEQUENCE
53
OPERATION
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• 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.
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.
54
OPERATION
Break-In Period
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 and drive components. Do not operate at full throttle
or high speeds during the first three hours of use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 41.
2. Check the engine oil level on the dipstick. See page 79. 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 56.
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.
55
OPERATION
Pre-Ride Checklist
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.
Item
Remarks
Page
Brake system/lever travel
Ensure proper operation
37
90
Brake fluid
Ensure proper level
38
Auxiliary brake
Ensure proper operation
40
Front suspension
Inspect, lubricate if necessary
77
Rear suspension
Inspect, lubricate if necessary
77
Steering
Ensure free operation
-
Tires
Inspect condition and pressure
93
Wheels/fasteners
Inspect, ensure fastener tightness
93
94
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
41
79
Coolant level (if applicable)
Ensure proper level
88
89
Coolant hoses (if applicable)
Inspect for leaks
Throttle
Ensure proper operation
36
122
Indicator lights/switches
Ensure operation
34
Engine stop switch
Ensure proper operation
35
Air filter, pre-filter
Inspect, clean
95
-
-
Air box sediment tube
Drain deposits whenever visible
Headlamp
Check operation, apply Polaris dielectric grease when lamp is replaced
35
96
Brake light/taillight
Check operation, apply Polaris dielectric grease when lamp is replaced
99
Riding gear
Wear approved helmet, goggles, and
protective clothing
10
56
-
OPERATION
Starting the Engine
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. Sit on the vehicle and move the engine stop switch to RUN.
NOTE: Do not press the throttle while starting the engine.
5. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.
6. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
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 contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of 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.
57
OPERATION
Hauling Cargo
2/3
1/3
Your ATV has been designed to carry or tow a certain amount of load.
Always read and understand the load distribution warning labels on the
vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals.
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.
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.
CAUTION
Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your ATV warranty.
Never install a hitch longer than 6 3/4"
(17 cm). Never install automotive
accessories on your Polaris ATV. Always
install Polaris-approved (or equivalent)
accessories designed for ATV use.
58
Maximum
6 3/4" (17 cm)
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:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
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 only one rack
increases the possibility of vehicle overturn.
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.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the
vehicle.
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.
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.
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.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on
the front rack.
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.
59
OPERATION
Driving Safely
Driving Procedures
1. Wear protective riding gear. See page 10.
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.
60
OPERATION
Driving Safely
Turning the Vehicle
Your ATV is equipped with a solid rear
axle, which drives both rear wheels
equally at all times. This means that the
wheel on the outside of the turn must
travel a greater distance than the inside
wheel when turning and the inside tire
must slip traction slightly. To turn, steer
in the direction of the turn, leaning your
upper body to the inside of the turn
while supporting your weight on the
outer footrest. 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.
61
OPERATION
Driving Safely
Driving on Slippery Surfaces
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.
62
OPERATION
Driving Safely
Driving Uphill
25° Maximum
Whenever traveling uphill, follow these precautions:
1. If your ATV is equipped with Active Descent Control, always
engage AWD before ascending a hill. See page 45.
2. Drive straight uphill.
3. Avoid steep hills (25° maximum).
4. Keep both feet on the footrests.
5. Shift your weight uphill.
6. Proceed at a steady rate of speed and throttle opening.
7. 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.
63
OPERATION
Driving Safely
Driving on a Sidehill (Sidehilling)
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!
64
OPERATION
Driving Safely
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. If your ATV is equipped with Active Descent Control, always
engage AWD before descending a hill. See page 45.
2. Shift your weight uphill.
3. Drive straight downhill.
4. Slow down.
5. Squeeze the brake lever gradually.
NOTE: Before operating your ATV, learn how to use the auxiliary brake for
emergency situations (if single-lever brakes become inoperable).
65
OPERATION
Driving Safely
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
1. Stop and lock the parking brake while keeping body weight uphill.
2. If your ATV is equipped with Active Descent Control, engage
AWD. See page 45.
3. Leave the transmission in forward and shut off the engine.
4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, 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.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
66
OPERATION
Driving Safely
Driving Through Water
Your ATV can operate through
water with a maximum recommended depth equal to the bottom of the footrests. Follow
these procedures when operating through water:
1. Determine water depths and
current before crossing.
2. Choose a crossing where
both banks have gradual
Maximum
inclines.
Depth
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 72. 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 102. Have
the vehicle serviced by your dealer at the first opportunity.
67
OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you're traveling on. Be
constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact with a
hidden obstacle. Not all obstacles are immediately visible. Travel with caution
in unfamiliar terrain.
68
OPERATION
Driving Safely
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. Use the
override button with caution as rearward vehicle speed is greatly
increased. Do not operate at wide open throttle.
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.
Operate the throttle just enough to maintain a desired speed
69
OPERATION
Driving Safely
Parking on an Incline
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.
70
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
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on the recoil cover or stator housing.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with European directives 97/24/EC and 89/336/
EEC.
71
MAINTENANCE
Periodic Maintenance Chart
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.
Record maintenance and service in the Maintenance Log beginning on
page 136.
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
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• 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.
72
Periodic Maintenance Chart
MAINTENANCE
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to
severe use.
E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
Q Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a Q could result in
component failure and lead to serious injury or death. Have an authorized
Polaris dealer perform these services.
73
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
Q Steering
-
Pre-Ride
-
X Front suspension
-
Pre-Ride
-
X Rear suspension
-
Pre-Ride
-
-
Pre-Ride
-
Tires
X Brake fluid level
-
Pre-Ride
-
X Brake lever travel
-
Pre-Ride
-
Brake system
-
Pre-Ride
-
Wheels/fasteners
-
Pre-Ride
-
Frame fasteners
Remarks
Make adjustments as need
ed. See Pre-Ride Checklist
on page 56.
-
Pre-Ride
-
X Engine oil level
-
Pre-Ride
-
X Air filter, pre-filter
E
-
Daily
-
Inspect; clean often; replace
as needed
X Air box sediment
tube
-
Daily
-
Drain deposits when visible
Coolant
(if applicable)
-
Daily
-
Check level daily, change
coolant every 2 years
-
Daily
-
Check level daily, add as
needed
-
Daily
-
Check operation; apply
dielectric grease if replacing
lamps
-
Weekly
-
Inspect; replace as needed
-
Weekly
-
Drain water as needed,
check often if operating in wet
conditions
10 H
Monthly
100 (160)
Inspect periodically
X ADC fluid
(ADC models)
Headlight/taillight/
worklight
X Air filter,
E main element
Recoil housing
(if applicable)
X Brake pad wear
Q
20 H
Monthly
200 (320)
Check terminals; clean; test
X Demand drive fluid
Battery
25 H
Monthly
250 (400)
Inspect level; change yearly
X Rear gearcase oil
(if equipped)
25 H
Monthly
250 (400)
Inspect level; change yearly
X Transmission oil
25 H
Monthly
250 (400)
Inspect level; change yearly
X Engine breather
E filter (if equipped)
25 H
Monthly
250 (400)
Inspect; clean if needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
74
Periodic Maintenance Chart
Item
MAINTENANCE
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
X General
lubrication
50 H
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
Q Throttle Cable/
E ETC Switch
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H
6M
500 (800)
Inspect duct for proper sealing/air leaks
Drive belt
50 H
6M
500 (800)
Inspect; adjust; replace as
needed
Cooling system
(if applicable)
50 H
6M
1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
X Engine oil change
100 H
6M
1000 (1600) Perform a break-in oil change
at one month
X Oil filter change
100 H
6M
1000 (1600) Replace with oil change
Q Valve clearance
100 H
12 M
1000 (1600) Inspect; adjust
Fuel system
100 H
12 M
1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
X Radiator
(if applicable)
100 H
12 M
1000 (1600) Inspect; clean external
surfaces
X Cooling hoses
(if applicable)
100 H
12 M
1000 (1600) Inspect for leaks
X Engine mounts
100 H
12 M
1000 (1600) Inspect
100 H
12 M
1000 (1600) Inspect
Q Spark plug
100 H
12 M
1000 (1600) Inspect; replace as needed
X Wiring
100 H
12 M
1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
E
Exhaust muffler/
pipe
E
75
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Remarks
Miles
(Km)
Q Clutches (drive
100 H
12 M
1000 (1600) Inspect; clean; replace worn
parts
Q Front wheel
100 H
12 M
1000 (1600) Inspect; replace as needed
Q Brake fluid
200 H
24 M
2000 (3200) Change every two years
Q ADC fluid
200 H
24 M
2000 (3200) Change every two years
X Fuel filter
200 H
24 M
2000 (3200) Check for leaks around lines.
Replace every 2 years, more
often under
extreme conditions.
300 H
36 M
3000 (4800) Clean out
and driven)
bearings
(ADC models)
Q
E
Spark arrestor
Q Toe adjustment
Headlight aim
-
Inspect periodically; adjust
when parts are replaced
-
Adjust as needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
76
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 72. Items not
listed in the chart should be lubricated at the General Lubrication
interval.
NOTE: The a-arms and lower control arms are lubricated at the factory, and
no additional lubrication will be needed. However, if these components
are subjected to severe use, grease zerks have been provided for
additional lubrication at the user's discretion.
Item
Lube
Method
Engine Oil
Polaris Premium 4 Synthetic Add to proper level on dipstick.
0W40
Brake Fluid
DOT 4 Only
Maintain level between fill lines.
See page 38.
Transmission Oil
Polaris AGL Synthetic
Gearcase Lube
See page 83.
Demand Drive Fluid
(Front Gearcase)
Demand Drive LT Premium
Fluid
See page 84.
ADC Fluid
Polaris ADC Fluid
Maintain level between fill lines.
See page 86.
Front Prop Shaft Yoke
Polaris Premium U-Joint
Lube
Grease fittings (3 pumps maximum) every 500 miles, before
long periods of storage, or after
pressure washing or submerging.
Front Prop Shaft Yoke
77
MAINTENANCE
Engine Oil
Oil Recommendations
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 127 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 0W40. 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.
78
Engine Oil
MAINTENANCE
Oil Level
Access the oil dipstick and fill tube
from the left side of the ATV.
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.
Safe Range
{
1. Position the vehicle on a level
surface.
2. Start the engine. Allow it to idle
for 20-30 seconds. Stop the
engine.
3. Remove the dipstick. Wipe it
dry with a clean cloth.
4. Reinstall the dipstick completely.
5. Remove the dipstick and check
the oil level. Maintain the oil
level in the safe range. Do not
overfill.
Dipstick
Add Oil
Safe
79
MAINTENANCE
Oil and Filter Change
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin.
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 72. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to idle for two to three minutes.
3. Stop the engine.
4. Clean the area around the drain
plug.
5. Place a drain pan under the oil
Screen
Fitting
tank.
Drain
6. Remove the drain plug. Allow
Plug
the oil to drain completely.
7. Install a new sealing washer on
the drain plug.
New Sealing Washer
NOTE: The sealing surfaces on drain
plug and crankcase should be
clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque
to 14-17 ft. lbs. (19-23 Nm).
9. Disconnect the lower oil delivery hose and remove the screen
fitting from the oil tank. Clean
the fitting.
Alignment Mark
NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE
seal tape.
10. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.
NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.
(34 Nm).
11. Reattach the oil line.
80
Oil and Filter Change
MAINTENANCE
12. Place shop towels beneath the oil
filter. Using an oil filter wrench,
turn the filter counterclockwise to
remove it.
13. Using a clean dry cloth, clean the
filter sealing surface on the crankcase.
14. 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.
15. Install the new filter and rotate it clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.
16. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crankcase.
NOTE: The sealing surfaces on the drain plug and crankcase should be clean
and free of burrs, nicks or scratches.
17. Reinstall the drain plug.Torque to 14 ft. lbs. (19 Nm).
18. Remove the dipstick.
19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.
NOTE: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.
20. Place the transmission in PARK.
21. Lock the parking brake.
22. Prime the oil pump using the procedure on page 82. Then stop
the engine and inspect for leaks.
23. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
24. Dispose of used filter and oil properly.
81
MAINTENANCE
Oil and Filter Change
Oil Pump Priming
This priming procedure must be
Tank
performed whenever the oil hose
2"
connection between the oil tank and
(5 cm)
pump inlet has been disconnected.
1. Clamp or pinch off the vent line
approximately 2" (5 cm) from
the oil tank, between the end of
Clamp
the oil tank vent fitting and the
Pressure
vent line's pressure relief slit.
Relief Slit
2. Start the engine. Allow it to idle
for 10-20 seconds.
3. Remove the vent line clamp. If the line is bled properly, you should
hear a rush of air, indicating that the line is properly primed and
ready for operation.
NOTE: If you do not hear air, the line has not bled. Repeat the priming procedure.
82
Transmission Oil
MAINTENANCE
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 72. Maintain the
oil level at the bottom of the fill plug hole threads. We recommend the
use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page
127 for the part numbers of Polaris products.
The fill plug is located on the left side of the ATV, under the rear fender,
behind the wheel.
The drain plug is located on the right side of the gearcase, on the right
side of the ATV, behind the wheel well.
Fill Plug
Drain Plug
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the fill plug.
3. Check the oil level.
4. Reinstall the fill plug.Torque
to 22 ft. lbs. (30 Nm).
5. Reinstall the footwell.
Fill Plug
83
MAINTENANCE
Transmission Oil
Oil Change
1. Remove the fill plug.
2. Place a drain pan under the
gearcase.
3. Remove the drain plug.
Allow the oil to drain completely.
4. Clean and reinstall the drain
Drain
plug. Torque to 22 ft. lbs.
Plug
(30 Nm).
5. Add 32 oz. (948 ml) of the recommended oil.
6. Reinstall the fill plug. Torque to 22 ft. lbs. (30 Nm).
7. Check for leaks.
8. Dispose of used oil properly.
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 72. We recommend the use of Demand Drive LT Premium Fluid. Use of other
fluids may result in improper operation of components. See page 127 for
the part numbers of Polaris products.
Maintain the fluid level at
Fill
the bottom of the fill hole
Plug
threads. See below for
capacity.
The fill plug is located on
the right side of the
demand drive unit. The
drain plug is located on the
bottom right side of the
Drain Plug
unit.
Fill Level
Demand Drive Capacities
84
Standard Demand Drive
9 oz. (265 ml)
Demand Drive with ADC
9.3 oz. (275 ml)
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Check
1. Position the vehicle on a level surface. Remove the fill plug. Check
the fluid level.
2. Add the recommended demand drive fluid as needed to bring the
level to the bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug. Place a
drain pan under the demand drive unit.
2. Remove the drain plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).
4. Add the recommended fluid. See page 84 for capacity. Maintain the
fluid level at the bottom of the fill hole threads.
5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
6. Check for leaks. Dispose of used fluid properly.
85
MAINTENANCE
Active Descent Control (ADC) Fluid
If your vehicle is equipped with Active Descent Control, there are two
fluid levels that must be maintained (demand drive fluid and ADC
fluid). See page 84 for demand drive fluid maintenance. Check and
change the ADC fluid level at the intervals outlined in the Periodic
Maintenance Chart beginning on page 72. Maintain the fluid level
between the minimum and maximum marks on the reservoir. We recommend the use of Polaris ADC Fluid. See page 127 for the part numbers
of Polaris products.
NOTE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
1. Open the front box cover and pull
open the access door.
2. View the fluid level in the reservoir.
3. If the level is below the minimum
mark, remove the cap and add the
recommended fluid.
4. Reinstall the cap. Secure the access
door. Secure the box cover.
ADC Fluid Reservoir
86
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Change
1. Position the vehicle on a level surface. Before performing the fluid
change, allow the vehicle to sit for at least 30 minutes.
2. Thoroughly clean the areas around and on the ADC reservoir and
bleeder valves (one on each side of the differential).
3. Remove the reservoir cap and diaphragm assembly. Use a shop
towel or suction tool to remove debris from the fluid and reservoir.
NOTE:
Debris in the reservoir may result in inadequate bleeding and reduced
performance of the system.
4. Fill the reservoir to the maximum line with fresh ADC fluid.
5. Remove the protective caps from the bleeder valves.
6. Slowly loosen one of the valves (turn counter-clockwise) and allow
fluid and trapped air to flow from the fitting. Close the valve when
clean fluid begins to flow. Repeat this step for the remaining valve.
IMPORTANT: Close the bleeder valves before the reservoir fluid level drops
below the minimum fill line. Adding fluid to an empty resevoir will result in
trapped air. If the level drops below the minimum line, add fluid to the maximum
line and repeat step 6 before proceeding.
7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.
8. Add fresh ADC fluid to the reservoir until the level is between the
minimum and maximum marks. Make sure the reservoir is free of
debris.
9. Reinstall the cap securely.
10. Clean up any drips or spills.
87
MAINTENANCE
Cooling System
The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.
NOTE: Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
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 127 for the part
numbers of Polaris products.
NOTE: Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Recovery Bottle Coolant
The recovery bottle is located on
the left side of the vehicle.
1. Remove the left side panel.
See page 92.
2. Maintain the coolant level
between the minimum and
maximum marks on the bottle (when the fluid is cool).
3. Add coolant as needed.
88
MAINTENANCE
Cooling System
Radiator Coolant
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.
Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. 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.
1. Open the front box cover
and pull open the access
door.
2. Remove the pressure cap.
3. Using a funnel, slowly add
coolant through the radiator filler neck.
4. Reinstall the pressure cap.
5. Secure the access door.
6. Secure the box cover.
Radiator Cap
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.
89
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are selfadjusting.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING
An over-full master cylinder may cause brake drag or brake lock-up, which
could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.
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.
1. Always keep brake fluid at an adequate
level. See page 38.
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. Replace brake pads when
they are worn to 3/64" (1 mm).
3/64" (1 mm)
5. Check the security and surface condition
of the disc.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 40.
90
MAINTENANCE
Toe Alignment
WARNING
Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized Polaris dealer.
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.
1. Place the handlebars
in a straight-ahead
position.
2. Place stands in front
of the vehicle, perpendicular to the rear
tires.
String
3. Tie an elastic string
around the stands,
making sure the
string just touches
Rear of
the side surface of
Front Rim
the rear tires on each
side of the vehicle
and goes around the
stands in front of the
Front of
vehicle.
Front Rim
4. Measure the distance from the string
to the rim at the front
Stands
and rear of the front
rim. Rear measurement should be 1/16"
to 1/8" (2-3 mm)
more than the front
measurement.
NOTE: If you discover improper alignment, see your Polaris dealer for service.
91
MAINTENANCE
Steering Assembly
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.
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.
Step 1
Step 2
Step 3
Footwell Removal
1. Remove the four screws on
the bottom of the footwell.
2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.
3. Remove the footwell.
Rivets
Screws
92
MAINTENANCE
Tires
Refer to the specifications section beginning on page 128 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 as described on the decal on your ATV and in
the owner's manual.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
1/8" (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.
93
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 hub with the valve stem toward the outside
and 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)
27 ft. lbs.
(37 Nm)
Cast Aluminum
Steel
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loosened for maintenance service.
94
Nut Type
Nut Torque
Lug Nut
90 ft. lbs. (122 Nm)
2-Piece Flange Nut
27 ft. lbs. (37 Nm)
MAINTENANCE
Air Filter
Pre-Filter
1. Remove the seat.
2. Release the air box cover
clips, and remove the air box
cover.
3. Loosen the clamp and
remove the filter.
4. Remove the fabric type prefilter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter.
NOTE: Install a new main filter if
needed.
Main Filter
Breather
Filter
6. Reinstall the filter into the air box and tighten the clamp. Do not
over-tighten the clamp, as filter damage could occur.
7. Reinstall the air box cover and the seat.
Breather Filter/Hose
The breather filter is on the hose that runs between the engine and air
box. See illustration above.
1. Remove the left side panel. See page 92.
2. Remove the hose clamps from the filter and pull the filter out of the
hoses.
3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace a damaged or
clogged filter.
4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.
5. Reinstall the filter and hose 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 it for service.
95
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.
96
MAINTENANCE
Lights
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.
Low Beam Adjustment
Phillips Screw
The low beam can be adjusted slightly
upward or downward.
1. Loosen the phillips screw located
at the rear of the headlamp.
2. Tilt the headlamp upward or
downward.
3. Tighten the screw.
97
MAINTENANCE
Lights
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 head-
lamp 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.
98
5 1/8"
(13 cm)
Lights
MAINTENANCE
Lower Headlamp Replacement
1. Turn the back of the headlight
harness counterclockwise and
pull the harness assembly away
from the headlight assembly.
2. Remove the headlamp and install
the new headlamp.
3. Reinstall the harness assembly
into the headlight assembly.
4. Turn the headlight harness clockwise to secure the headlamp.
Harness
Taillight/Brakelight/Worklight (if equipped) Lamp
Replacement
1. Remove the harness connector
Connector
from the back of the light
assembly.
2. Turn the lamp counterclockwise to remove it.
3. Apply dielectric grease to the
socket and install the new
Lamp
lamp.
4. Reinstall the harness connector.
5. Test the light for proper operation.
99
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 128 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
Plug Condition
Torque Specification
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. Check the spark
plug firing end condition 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 101.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
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. Torque to specification.
100
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
fuel.
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 or incorrect throttle body adjustments.
Recoil Housing
Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the drain screw on the
bottom of the recoil housing.
5. 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.
101
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.
1. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
2. Move the ATV to dry land or at the very least, to water below the
footrests.
3. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
4. Remove the spark plug.
5. Turn the engine over several times using the electric start.
6. Dry the spark plug. Reinstall the plug or install a new plug.
7. Attempt to start the engine. If necessary, repeat the drying procedure.
8. Take the ATV to your dealer for service as soon as possible, whether
you succeed in starting it or not.
9. If water has been ingested into the PVT, follow the procedure on
page 106 for drying out the PVT.
102
MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark arrestor
could result in serious injury or death.
The exhaust system can get extremely hot. Do not perform service on the
spark arrestor while the system is hot. Allow components to cool sufficiently
before proceeding.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while
purging. Never run the engine in an enclosed area. Exhaust contains
poisonous carbon monoxide gas. Never go under the vehicle while it's
inclined.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrestor clean-out
plug from the bottom of the
muffler.
Exhaust
2. Place the transmission in
Outlet
PARK.
3. Start the engine.
Clean-Out Plug
4. Quickly squeeze and release
the 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 to 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.
103
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.
104
PVT System
MAINTENANCE
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 km/h), due to the
system's dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h) 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 km/h), 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, wears clutch components 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.).
105
MAINTENANCE
PVT System
When To Use Low Range and High Range
Condition
Operating at speeds less than 7 MPH (11 km/h)
Range to Use
Low
Towing heavy loads
Low
Operating in rough terrain (swamps, mountains, etc.)
Low
Operating at speeds greater than 7 MPH (11 km/h)
High
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. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches.
NOTE: Do not hold the throttle wide open for more than 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
106
MAINTENANCE
Battery
Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its
flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.
Conventional Battery
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.
107
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.
2.
3.
4.
5.
6.
Disconnect the battery hold-down strap.
Remove the battery cover.
On conventional batteries, remove the battery vent tube.
Disconnect the black (negative) battery cable first.
Disconnect the red (positive) battery cable last.
Lift the battery out of the ATV. Be careful not to tip a conventional
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.
108
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 111 before installing
the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed batteries do not have a 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. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Install the battery cover.
8. Secure the battery hold-down strap.
9. Verify that cables are properly routed.
NOTE: Cables should be safely tucked away at the front and rear of the battery.
109
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 selfdischarge. 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. See page 127 for the part numbers of
Polaris products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.
Add only distilled water. Tap water
contains minerals that are harmful to
a battery.
110
Lower
Mark
Upper
Mark
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 108.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3. Reinstall the battery. See page 109. Make sure the positive terminal
is toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger,
use the guidelines on the next page for recharging.
111
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
NOTE: Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
Voltage
Action
(Using constant current
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None required
75%-100%
12.5-12.8 volts
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
None, check at 3
mos. from date of
manufacture
May need slight
charge, if no
charge given,
check in 3 months
Needs charge
Needs charge
0%-25%
11.5 volts or less
112
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
Cleaning and Storage
MAINTENANCE
Washing the Vehicle
Keeping your Polaris vehicle clean will not only improve its appearance
but it can also extend the life of various components.
CAUTION
High water pressure may damage components. Polaris recommends
washing the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage
plastic surfaces. Do not allow these types of products to contact the vehicle.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
113
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the following items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• 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
Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
114
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.
115
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 113.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
Follow the instructions on the container for the recommended
amount.
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 entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 80.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
95.
2. Clean the air box.
3. Drain the sediment tube.
4. Clean or replace the breather filter. See page 95.
Recoil Housing
Drain the recoil housing. See page 101.
116
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 72.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several
minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of
clear 1/4" hose and a small plastic squeeze bottle filled with the premeasured amount of oil.
NOTE: Do this carefully! If you miss the plug hole, oil will drain from the spark
plug cavity into the hole at the front of the cylinder head, and appear to
be an oil leak.
3. Reinstall the spark plug. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
6. If Polaris fuel system additive is not used, the fuel tank, fuel lines,
and injectors should be completely drained of gasoline.
117
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 72.
Battery Storage
See pages 110-111 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: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
Accessories
Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. Polaris also has a
wide range of additional accessories available for your ATV. Always
install accessories that are approved for ATV use. Please see your
Polaris dealer.
118
Transporting the ATV
MAINTENANCE
Follow these procedures when
transporting the vehicle.
1. Stop the engine.
2. Place the transmission in
PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap
and seat.
5. 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.
6. Remove the key to prevent
loss during transporting.
119
ADJUSTMENTS
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is adjusted
by rotating the adjuster either clockwise
or counterclockwise to increase or
decrease spring tension.
NOTE: Accessory springs are available
through your Polaris dealer.
120
Adjuster
ADJUSTMENTS
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 handlebar
bolts.
3. Adjust the handlebar to the
desired height.
NOTE: 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 of the clamp
blocks.
Handlebar
Bolts
121
ADJUSTMENTS
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your Polaris dealer for adjustment.
Throttle Cable Freeplay
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.
Boot
Lock Nut
122
Adjuster
Drive Belt Wear/Burn
Possible Cause
Driving onto a pickup or
tall trailer in high range
Starting out going up a
steep incline
Driving at low RPM or
ground speed (3-7 MPH)
Insufficient warm-up at
low ambient temperatures
TROUBLESHOOTING
Solution
Use low range during loading.
Use low range or turn around using the K-turn (see page
66).
Drive at a higher speed or use low range more frequently.
See page 106.
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow/easy clutch engage- Use the throttle quickly and effectively.
ment
Towing/pushing at low
Use low range only.
RPM/low ground speed
Utility use/plowing
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
Shift the transmission to low range and carefully use fast,
objects from a stopped
brief, aggressive throttle application to engage clutch.
position
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water Dry out the PVT. See page 106. Inspect clutch seals for
or snow ingestion into the damage if repeated leaking occurs.
PVT system
Clutch malfunction
See your Polaris dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
Always warm up the belt by operating below 30 mph for
warm up belt
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch. See page 55.
123
TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Low battery voltage
Loose battery connections
Loose solenoid connections
Solution
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Clogged fuel filter
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plug(s)
No spark to spark plug
Water or fuel in crankcase
Low battery voltage
Mechanical failure
Solution
Refuel, cycle key to ON position three
times for 5 seconds each, then start
Replace the filter
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs, verify stop switch is on
Immediately see your Polaris dealer
Recharge the battery to 12.8 VDC
See your dealer
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Loose ignition connections
Water present in fuel
124
Solution
Inspect, clean and/or replace spark
plug(s)
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
Check all connections and tighten
Replace with fresh recommended fuel
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
TROUBLESHOOTING
Solution
Replace with recommended fuel
See your dealer
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Low battery voltage
Kinked or plugged fuel tank vent line
Incorrect fuel
Clogged air filter
Reverse speed limiter malfunction
Electronic throttle control malfunction
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Kinked or plugged fuel tank vent line
Low octane fuel
Clogged fuel filter
Incorrect fuel
Possible Rich Fuel Cause
Fuel is very high octane
Stopping/starting without adequate
warm-up
Incorrect fuel
Clogged air filter
Solution
Inspect, clean and/or replace spark
plug(s)
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Solution
Add or change fuel, clean the fuel system
Inspect and replace
Replace with recommended fuel
Replace filter
Replace with recommended fuel
Solution
Replace with lower octane fuel
Allow engine to warm up before operating and/or stopping
Replace with recommended fuel
Inspect and clean or replace
125
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Incorrect fuel
Clogged air filter
Reverse speed limiter malfunction
Electronic throttle control malfunction
Other mechanical failure
Overheated engine
Solution
Refuel, cycle key to ON position three
times for 5 seconds each, then start
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark
plug(s)
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Clean radiator screen and core, clean
engine exterior, see your dealer
Engine Overheating
Possible Cause
Debris lodged in screen
Plugged Radiator
126
Solution
Remove and clean the screen. Pull on the
top portion of the screen, then remove the
lower portion.
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.
POLARIS PRODUCTS
Part
Number
Description
2872889
2871326
2870652
2872189
2872893
2871956
Engine Lubricant
Fogging Oil (12 oz. Aerosol)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)
Premium AGL Synthetic Gearcase Lube (gal./3.8 l)
Active Descent Control (ADC) Fluid
Premium ATV Angle Drive Fluid (8 oz./237 ml)
Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)
Pump for Gallon (3.8 l) Jug
Demand Drive LT Premium Fluid (8 oz./237 ml)
Coolant
60/40 Coolant (gal./3.8 l)
60/40 Coolant (qt./.95 l)
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season
Premium All Season Grease (3 oz./89 ml cartridge)
Premium All Season Grease (14 oz./414 ml cartridge)
Starter Drive Grease
Premium U-Joint Lube (3 oz./89 ml cartridge)
Premium U-Joint Lube (14 oz./414 ml cartridge)
Dielectric Grease (NyogelTM)
Chain Lube, Aerosol (6.25 oz./185 ml)
Chain Lube, Aerosol (16 oz./473 ml)
Additives / Miscellaneous
Brake and Clutch Cleaner
Carbon Clean Plus
Fuel Stabilizer
DOT 4 Brake Fluid
Engine Degreaser
LoctiteTM 565 Thread Sealant
2871076
Polaris Battery TenderTM Charger
2870791
2871281
2871844
2873602
2873603
2876144
2871653
2872276
2870465
2876251
2871323
2871534
2871312
2871322
2871423
2871460
2871515
2871551
2871329
2872073
2872348
127
SPECIFICATIONS
Sportsman 500 EFI
Gross Vehicle Weight
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Front Rack/Storage Box Capacity
Rear Rack/Storage Box Capacity
Receiver Hitch Tongue Capacity
Hitch Towing Rating
Unbraked Trailer Towing
Capacity*
Overall Length
Overall Width
Overall Height
Wheelbase
Ground Clearance
Dry Weight
Minimum Turning Radius
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Fuel System
Ignition System
Ignition Timing
Spark Plug / Gap
Lubrication System
Driving System Type
Front Suspension
Rear Suspension
* Based on EU Directive 76/432/EC
128
1200 lbs. (544 kg)
4.13 gal. (15.6 l)
2 qts. (1.9 l)
2.7 qts. (2.5 l)
90 lbs. (40.8 kg)
180 lbs. (81.6 kg)
120 lbs. (54 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
1225 lbs. (556 kg)
1786 lbs. (810 kg)
83 in. (211 cm)
48 in. (122 cm)
48 in. (122 cm)
50.5 in. (128.3 cm)
11.25 in. (28.5 cm)
728 lbs. (330 kg) (base model) (weight of other
models may vary)
65 in. (165 cm) unloaded
EH50PLE
499 cc
92 x 75
350 w
10.2:1
Electronic Fuel Injection
Electronic Ignition
13 +/- 3 BTDC @ 1150 RPM, engine warm
NGK BKR6E / .035 in. (0.9 mm)
Dry Sump
Automatic PVT (Polaris Variable Transmission)
MacPherson strut with 8.2" (21 cm) travel
Progressive rate with 9.5" (24 cm) travel
SPECIFICATIONS
Sportsman 500 EFI
Shift Type
Gear Reduction, Low
Gear Reduction, Reverse
Gear Reduction, Forward
Drive Ratio, Front
Tires/Pressure, Front
Tires/Pressure, Rear
Brakes, Front
Brakes, Rear
Brake, Auxiliary
Brake, Parking
Headlight
Taillights
Brake Light
Instrument Cluster
Side Lever (H/L/N/R/P)
23.91:1
16.30:1
10.49:1
3.82:1
26x8-12 / 5 psi
26x11-12 / 5 psi
Single-Control Hydraulic Disc
Single-Control Hydraulic Disc
Foot-Activated Hydraulic Disc
Hydraulic lock, all wheel
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (37.5 watt)
8.26 watts
26.9 watts
LCD
Clutching (EBS Models)
Altitude
Meters
(Feet)
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
0-1800
(0-6000)
10 WH
PN 5630710
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS
PN 5131674
1800-3700
(6000-12000)
10 RH
PN 5630709
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS
PN 5131674
NOTE: *EBS models require no helix/spring adjustment
Clutching (Standard Models)
Altitude
Meters
(Feet)
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix and
Spring
Setting
0-1800
(0-6000)
10 WH
PN 5630710
Blue/Green
PN 7041157
Black
PN 7041782
41-37°
PN 5132344
2+2
1800-3700
(6000-12000)
10 RH
PN 5630709
Blue/Green
PN 7041157
Black
PN 7041782
41-37°
PN 5132344
2+2
129
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 troublefree operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
130
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.
131
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 8340.1(c) for at least 1000 hours when subjected to normal use and
when maintenance and installation are in accordance with Polaris recommendations.
132
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.
133
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
134
U.S.A. EPA Emissions Limited Warranty
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.
135
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and services performed.
DATE
136
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
137
INDEX
G
Gear Selector. . . . . . . . . . . . . . . . . . . 42
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 11
H
Hand Brake . . . . . . . . . . . . . . . . . . . . 90
Handlebar Adjustment . . . . . . . . . . 121
Hauling Cargo. . . . . . . . . . . . . . . 58-59
Headlight Housing Replacement . . . 98
Headlight Lamp Replacement . . . . . 96
Headlight Switch. . . . . . . . . . . . . . . . 35
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 10
High Beam Adjustment . . . . . . . . . . 97
High Range Use . . . . . . . . . . . . . . . 106
I
Idle RPM Adjustment . . . . . . . . . . . 122
Immersion Maintenance . . . . . . . . . 102
Instrument Cluster. . . . . . . . . . . . 46-53
K
Key Switch . . . . . . . . . . . . . . . . . . . . 35
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 66
L
Lights
Headlight Housing . . . . . . . . . . 98
Headlight Lamp . . . . . . . . . . . . 96
High Beam Adjustment . . . . . . 97
Low Beam Adjustment . . . . . . . 97
Lower Headlamp Replacement. 99
Taillight/Brakelight/Worklight . 99
Low Beam Adjustment . . . . . . . . . . . 97
Low Range Use. . . . . . . . . . . . . . . . 106
Lower Headlamp Replacement. . . . . 99
Lubrication Guide . . . . . . . . . . . . . . . 77
M
Maintenance Chart . . . . . . . . . . . 72-76
Master Cylinder . . . . . . . . . . . . . . . . 38
Mode Switch . . . . . . . . . . . . . . . . . . . 34
Modifications . . . . . . . . . . . . . . . . . . 18
N
Noise Emission Control System . . . . 71
O
Oil
Engine . . . . . . . . . . . . . . . . . 78-79
Transmission. . . . . . . . . . . . 83-84
Oil and Filter Change . . . . . . . . . 80-82
Oil Level, Engine . . . . . . . . . . . . . . . 79
Oil Pump Priming . . . . . . . . . . . . . . . 82
Oil Recommendations . . . . . . . . . . . 78
Operation on Public Lands . . . . . . . . 71
Operator Safety . . . . . . . . . . . . . . 12-33
Override Switch . . . . . . . . . . . . . . . . 34
P
Parking Brake . . . . . . . . . . . . . . . . . . 39
Parking on an Incline . . . . . . . . . . . . 70
Periodic Maintenance Chart . . . . 72-76
Polaris Product List. . . . . . . . . . . . . 127
Polishing the Vehicle . . . . . . . . . . . 114
Pre-Ride Checklist . . . . . . . . . . . . . . 56
PVT Break-In . . . . . . . . . . . . . . . . . . 55
PVT Drying . . . . . . . . . . . . . . . . . . 106
PVT System . . . . . . . . . . . . . . 104-106
R
Recoil Housing . . . . . . . . . . . . . . . . 101
Recoil Starter . . . . . . . . . . . . . . . . . . 43
Reverse Operation . . . . . . . . . . . . . . 69
Reverse Override Switch . . . . . . . . . 34
Rider Information Center . . . . . . 47-53
Riding Gear. . . . . . . . . . . . . . . . . 10-11
S
Safety Decals
"No Passenger" Warning . . . . . . 8
Age 16 Warning . . . . . . . . . . . . . 8
All Wheel Drive Switch . . . . . . . 9
Clutch Cover Warning . . . . . . . . 9
Discretionary Warning . . . . . . . . 7
General Warning. . . . . . . . . . . . . 6
Hitch Capacity Label . . . . . . . . . 9
Rack Warning, Front and Rear . . 9
Reverse Override Warning . . . . . 9
Tire Pressure/Load Warning. . . . 7
Safety Training . . . . . . . . . . . . . . . . . 13
Service Interval Programming . . . . . 51
Severe Use . . . . . . . . . . . . . . . . . . . . 72
Side Panel Removal . . . . . . . . . . . . . 92
Sidehilling. . . . . . . . . . . . . . . . . . . . . 64
Signal Words . . . . . . . . . . . . . . . . . . 14
139
INDEX
A
C
Accessories . . . . . . . . . . . . . . . . . . 118
Active Descent Control Fluid . . . 86-87
Active Descent Control System. . . . 45
ADC System . . . . . . . . . . . . . . . . . . 45
Age Restrictions. . . . . . . . . . . . . . . . 12
Air Filter . . . . . . . . . . . . . . . . . . . . . 95
All Wheel Drive System . . . . . . . . . 44
Auxiliary Foot Brake . . . . . . . . . . . . 90
AWD Switch . . . . . . . . . . . . . . . . . . 44
AWD System . . . . . . . . . . . . . . . . . . 44
Coolant Bottle . . . . . . . . . . . . . . . . . . 88
Coolant, Radiator. . . . . . . . . . . . . . . . 89
Cooling System . . . . . . . . . . . . . . 88-89
Corrosion Removal, Chrome. . . . . . 115
Crankcase Emission Control System. 71
B
Battery
Charging (Conventional ) . . . 111
Charging (Sealed ) . . . . . . 111-112
Conventional . . . . . . . . . . . . . 107
Fluid (Conventional ). . . . . . . 110
Installation . . . . . . . . . . . . . . . 109
Removal. . . . . . . . . . . . . . . . . 108
Storage . . . . . . . . . . . . . . . . . . 110
Belt Life . . . . . . . . . . . . . . . . . . . . . . 42
Boots . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Fluid, Auxiliary Foot Brake . 40
Brake Fluid, Main Brake System. . . 38
Brake Lever . . . . . . . . . . . . . . . . . . . 37
Brake, Foot . . . . . . . . . . . . . . . . 40, 90
Brake, Hand Lever. . . . . . . . . . . . . . 90
Brake, Parking . . . . . . . . . . . . . . . . . 39
Brakelight Lamp Replacement . . . . 99
Brakes . . . . . . . . . . . . . . . . . . . . . . . 90
Break-In Period . . . . . . . . . . . . . . . . 55
Breather Filter . . . . . . . . . . . . . . . . . 95
Breather Hose . . . . . . . . . . . . . . . . . 95
C
Camber Adjustment . . . . . . . . . . . . 120
Cargo Loading . . . . . . . . . . . . . . . 58-59
Caster Adjustment . . . . . . . . . . . . . 120
Chrome Wheel Care . . . . . . . . . . . 115
Cleaning and Storage. . . . . . . . 113-118
Clock, Setting Time . . . . . . . . . . . . . 49
Clothing . . . . . . . . . . . . . . . . . . . . . . 11
Clutching (EBS Models) . . . . . . . . 129
Clutching (Standard Models). . . . . 129
Cold Weather Operation . . . . . . . . . 57
Consumer Product Safety . . . . . . . . 18
138
D
Demand Drive Capacities . . . . . . . . . 84
Disengaging Active Descent Control 45
Drive Belt Wear/Burn . . . . . . . . . . . 123
Drivetrain Break-In . . . . . . . . . . . . . . 55
Driving Downhill. . . . . . . . . . . . . . . . 65
Driving in Reverse. . . . . . . . . . . . . . . 69
Driving on a Sidehill . . . . . . . . . . . . . 64
Driving on Slippery Surfaces . . . . . . 62
Driving Over Obstacles . . . . . . . . . . . 68
Driving Procedures . . . . . . . . . . . . . . 60
Driving Safely . . . . . . . . . . . . . . . 60-70
Driving Through Water . . . . . . . . . . . 67
Driving Uphill . . . . . . . . . . . . . . . . . . 63
E
Electromagnetic Interference. . . . . . . 71
Emissions Limited Warranty . . . . . . 135
Engaging Active Descent Control . . . 45
Engaging AWD . . . . . . . . . . . . . . . . . 44
Engine Break-In. . . . . . . . . . . . . . . . . 55
Engine Fogging . . . . . . . . . . . . . . . . 117
Engine Oil . . . . . . . . . . . . . . . . . . 78-79
Equipment Modifications . . . . . . . . . 18
Exhaust Emission Control System . . 71
Eye Protection . . . . . . . . . . . . . . . . . . 11
F
Fluid
ADC. . . . . . . . . . . . . . . . . . . 86-87
Brake . . . . . . . . . . . . . . . . . . . . . 38
Demand Drive . . . . . . . . . . . 84-85
Fluid Change
ADC. . . . . . . . . . . . . . . . . . . . . . 87
Demand Drive . . . . . . . . . . . . . . 85
Foot Brake, Auxiliary . . . . . . . . . . . . 40
Footwell Removal . . . . . . . . . . . . . . . 92
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 41
Fuel Recommendations . . . . . . . . . . . 41
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 54
Fuel Tank Cap . . . . . . . . . . . . . . . . . . 41
INDEX
S
T
Spark Arrestor . . . . . . . . . . . . . . . . 103
Spark Plugs
Inspection. . . . . . . . . . . . . 100-101
Recommendations . . . . . . . . . 100
Torque Specification . . . . . . . 100
Specifications. . . . . . . . . . 128-129
Spring Adjustment, Rear Shock . . 120
Starting the Engine . . . . . . . . . . . . . 57
Steering Assembly . . . . . . . . . . . . . . 92
Storage . . . . . . . . . . . . . . . . . . . 113-118
Storage Tips . . . . . . . . . . . . . . . 116-118
Switches
AWD Switch . . . . . . . . . . . . . . 44
Engine Stop Switch . . . . . . . . . 35
Headlight Switch . . . . . . . . . . . 35
Main Key Switch . . . . . . . . . . . 35
Mode/Reverse Override Switch 34
Worklight Switch. . . . . . . . . . . 35
Tires
Wheel Installation . . . . . . . . . . . 94
Wheel Nut Torque . . . . . . . . . . . 94
Wheel Removal . . . . . . . . . . . . . 93
Toe Alignment. . . . . . . . . . . . . . . . . . 91
Towing Loads . . . . . . . . . . . . . . . . . . 58
Training . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission . . . . . . . . . . . . . . . . . . . 42
Transmission Oil . . . . . . . . . . . . . 83-84
Transporting the ATV . . . . . . . . . . . 119
Turning Around on a Hill . . . . . . . . . 66
Turning the Vehicle . . . . . . . . . . . . . . 61
T
Taillight Lamp Replacement . . . . . . 99
Throttle Body Adjustment . . . . . . . 122
Throttle Cable Freeplay Adjustment 122
Throttle Lever . . . . . . . . . . . . . . . . . 36
Tire Tread Depth . . . . . . . . . . . . . . . 93
140
V
Vehicle Identification Numbers. . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 102
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
W
Warning Symbols . . . . . . . . . . . . . . . 14
Washing the Vehicle . . . . . . . . 113-114
Wheel Hub Tightening . . . . . . . . . . . 93
Wheel Installation . . . . . . . . . . . . . . . 94
Wheel Nut Torque Specifications . . . 94
Wheel Removal . . . . . . . . . . . . . . . . . 93
Worklight Lamp Replacement. . . . . . 99
Worklight Switch. . . . . . . . . . . . . . . . 35