Univex Trail Blazer User's Manual

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 1-800-342-3764 for assistance.
Copyright 2004 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.
2005 Trail Blazer Owner’s Manual P/N 9919472
2
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S Victory motorcycles
S RANGER utility vehicles
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 Parts, Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
POLARIS and POLARIS THE WAY OUT are registered trademarks of
Polaris Industries Inc.
LOCTITE is a registered trademark of LOCTITE Corporation.
3
4
TABLE OF CONTENTS
WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FEATURES AND CONTROLS . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 63
MAINTENANCE AND LUBRICATION . . . . . . . . . 64
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 103
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 106
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 107
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5
6
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
31XX
1
2
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number:
(right front side of engine crankcase)
Key Number (2):
7
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. 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 from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
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.
8
Operator Safety
SAFETY
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
9
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safety training course.
S Always avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
10
Operator Safety
SAFETY
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when possible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
11
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of accessories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE:
12
The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.
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.
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN HAPPEN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
WARNING
POTENTIAL HAZARD
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN HAPPEN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
14
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN HAPPEN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
16
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID THE
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
18
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never operate on hills too steep for the ATV or for your abilities.
Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for climbing
hills as described in the
owner’s manual.
Always check the terrain
carefully before ascending
any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
20
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Traveling downhill
improperly.
WHAT CAN HAPPEN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for traveling
down hills as described in
the owner’s manual.
NOTE: A special technique
is required when braking
while traveling downhill. See
page 54.
Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill
when possible.
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN HAPPEN
Improperly crossing or
turning as hills could cause
loss of control or overturn.
HOW TO AVOID THE
HAZARD
Never attempt to turn the
ATV around on any hill until
you’ve mastered the turning
technique (on level ground)
as described in the owner’s
manual. See page 55. 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.
22
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards
or improperly dismounting
while climbing a hill.
WHAT CAN HAPPEN
The vehicle could overturn.
HOW TO AVOID THE
HAZARD
Maintain steady speed
when climbing a hill.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the ATV begins rolling backwards:
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill.
Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 55.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
The ATV could collide with an obstacle or person, resulting in
severe injury.
HOW TO AVOID THE HAZARD
Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back slowly.
24
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which
could lead to an accident or overturn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable to enter water that exceeds the recommended
maximum depth (see page 56), travel slowly, balance your weight
carefully, avoid sudden movements, and maintain a slow and
steady forward motion. Do not make sudden turns or stops, and
do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for the ATV.
Always maintain proper tire pressure as specified.
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of the ATV
may cause changes in handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify the ATV through improper installation or use of
accessories. All parts and accessories added to the vehicle must
be genuine Polaris Industries Inc. or equivalent components
designed for use on this ATV and should be installed and used
according to approved instructions. See your authorized Polaris
ATV dealer for more information.
WARNING
POTENTIAL HAZARD
Overloading the ATV or carrying/towing cargo improperly.
WHAT CAN HAPPEN
Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow a
greater distance for braking.
Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 60.
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.
26
Operator Safety
SAFETY
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.
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
WARNING
Safe operation of this rider-active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturn and loss of control, which could result in severe injury or
death.
CAUTION
Always keep combustible materials away from the exhaust
system. Exposure to the hot components could result in a fire.
27
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals and other warnings on the
ATV carefully. If any of the decals shown 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.
WARNING
25°
operate this vehicle on HILLS steeper than 25 degrees
.
To prevent flipover on hilly terrain, when going up or down, use throttle
and brakes gradually.
DREVERSE operation can be dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.
DUse OVERRIDE for reverse speed limiter with caution. To prevent loss
of control, never activate override button with open throttle.
DPARKING BRAKE may relax when used for more than 5 minutes. When
parking on grades, leave shift in forward.
DNever
7172665
WARNING
7172566
WARNING
WARNING
S
S
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.
NO STEP
28
7172563
7172664
SAFETY
Safety Decals and Locations
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:
ALWAYS:
7172560
29
SAFETY
Safety Decals and Locations
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.
7172559
Under Seat
RH Swingarm
Chain Freeplay Is Important.
Adjust Freeplay to 3/16″ - 3/8″
DO NOT Overtension.
See Owner’s Manual.
Torque Nut on Eccentric Bolts:
To 30 Ft. Lbs. (For models
without a hitch).
To 40 Ft. Lbs. (For models with
a hitch).
7078572
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
OVERRIDE
SWITCH
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.
Reverse Speed is
limited.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST
PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
7171492
Canadian Certification Decal
30
7079906
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.
Select an approved helmet that meets or
exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards Institute
label (ANSI z90.1), or the Snell
Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for proper
eye protection. A pair of goggles or a
helmet face shield offer the best
protection for your eyes. They should
be kept clean and be of shatterproof
design (bearing the markings z2.1 or
VESC 8).
1
2
3
5
4
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
31
FEATURES AND CONTROLS
Electrical Switches
3
1
2
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.
Override Switch (1) (Reverse Speed Limiter) OFF RUN
OFF
This vehicle is equipped with a reverse speed
limiter system. To gain additional power while
backing, depress the override switch.
3
Main Switch (2) - To start the engine, slide the
stop switch to the center RUN position and turn the
main key switch clockwise past the ON position. Release the key when
the engine starts.
NOTE:
Turning off the main switch will shut off all electrical power to
the vehicle, including the lights.
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.
Engine Stop Switch (3) - The engine will not start or run when the
switch is in its OFF position. Its purpose is to provide the operator
with a quick means of engine shutdown in case of an emergency. To
stop the engine, slide the stop switch either right or left to the OFF
position.
NOTE:
32
Turning off the engine stop switch will shut off all electrical
power to the vehicle, including the lights.
FEATURES AND CONTROLS
WARNING
Do not start or operate an ATV with sticking or improperly
operating throttle controls, which could cause an accident and
lead to severe injury or death.
Always contact your dealer for service repairs if throttle problems
arise.
Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks during
operation.
Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
Throttle Lever
Engine speed and vehicle
movement are controlled by
pressing the throttle lever. The
throttle lever (1) is spring loaded.
Engine speed returns to idle when
the lever is released.
1
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
The Electronic Throttle Control (ETC) stops the engine in the
event of a throttle system malfunction and is provided for your
safety. Do not attempt to modify the ETC system or replace it
with any after market throttle mechanisms.
33
FEATURES AND CONTROLS
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.
Light Switches
The light switch is located on the
left handlebar (1). It’s used to turn
the lights on and off.
NOTE:
The lights won’t work
unless the key is in the
ON position and the shut-off
switch is in the RUN position.
1
Indicator Lights
With the engine running, verify the function of all indicator lights each
time the ATV is used.
NOTE:
The taillight is on whenever the main switch (key) is on. Turn
the key off to prevent battery drain.
2
3
1. Transmission Neutral Indicator
2. Transmission Reverse Indicator
3. Oil Warning (indicates a low oil level.
34
1
Brakes
FEATURES AND CONTROLS
1
Check the brake fluid level in the master
2
cylinder before each use of the ATV.
The master cylinder (1) is located on
the left handlebar.
1. Position the ATV on level ground
with the handlebars straight.
2. View the fluid level through the
indicator window (2) on the top of the master cylinder. This “eye”
will appear dark when the fluid level is full. When fluid needs to
be added, the eye will be clear.
WARNING
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
NOTE:
Under normal operation, the diaphragm extends into the
reservoir as fluid level drops. If the fluid level is low and the
diaphragm is not extended, a leak is likely and the diaphragm
should be replaced. Always fill the reservoir as needed
whenever the cover is loosened or removed to ensure proper
diaphragm operation. We recommend the use of Polaris
DOT 3 brake fluid. Do not overfill.
3. If the fluid level is low, add DOT 3 brake fluid only. See page 106
for the part numbers of Polaris products.
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.
35
FEATURES AND CONTROLS
Brake Lever
1
The front and rear brakes are applied by
squeezing the brake lever (1) toward the
handlebar. The front and rear brakes are
hydraulically activated disc type brakes
that are activated by only one lever.
Always test brake lever travel and master
cylinder fluid level before riding. When
squeezed, the lever should feel firm. Any sponginess would indicate a
possible fluid leak or low master cylinder fluid level, which must be
corrected before riding. Contact your dealer for proper diagnosis and
repairs.
WARNING
Operating the ATV with a spongy brake lever can result in loss of
braking, which could cause an accident. Never operate the ATV
with a spongy-feeling brake lever.
36
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.
Setting the Parking Brake
1. Squeeze and release the brake
lever (1) two or three times, then
squeeze and hold.
2. Push the park brake lock (2)
forward to engage the brake.
Release the brake lever.
3. To release the parking brake lock,
squeeze and release the brake
lever. It will return to its unlocked
position.
1
2
Important Safeguards
S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill
position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
37
FEATURES AND CONTROLS
Auxiliary Brake
WARNING
Aggressively applying the rear brake when backing downhill may
cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward. The
rear wheels may skid and slide sideways, causing loss of control
and serious injury or death.
The auxiliary brake (1), is
located on the inside of the right
1
floor board and is operated by
the right foot. The auxiliary
brake serves as a backup to the
main brake system if the main
system becomes inoperative.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat or near the foot brake. Maintain
the fluid level between the maximum and minimum marks.
38
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 47 for correct choke and throttle settings during
starting.
Fuel Valve
The fuel valve (1) is located on the left side of
the vehicle, below the fender. It has three
positions:
OFF: For vehicle storage and when transporting.
ON: For normal operation.
RES: For reserve supply if main
supply is exhausted.
NOTE:
There’s about a 7 to 10 mile (11.2 to 16 km) range on
reserve gas. Always refill the gas tank 1
as soon as possible2
after using the reserve supply.
Always return valve to ON position
after refueling.
Fuel Tank
The fuel tank filler cap (2) is located
directly below the handlebar. Use
either leaded or unleaded gasoline with
a minimum pump octane number of
87=(R+ M/2) octane. Refer to the
specifications section beginning on
page 103 for capacities.
Fuel Filter
Replace the in-line fuel filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 65. Do not attempt to clean the
fuel filter.
39
FEATURES AND CONTROLS
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well
ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause loss of
consciousness or death in a short time.
S Turn the fuel valve off whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
40
FEATURES AND CONTROLS
Oil Injection Tank
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV.
Never substitute or mix oil brands.
To avoid serious engine damage, always top off the oil level when
refueling.
The oil injection tank filler cap (1)
is located on the front of the
vehicle. Refer to the specifications
section beginning on page 103
for capacities.
1
41
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector (1)
is located on the right side of the ATV.
F
F: Forward
N: Neutral
N
R: Reverse
1
R
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.
Whenever the ATV is left unattended, always place the transmission in
gear and lock the parking brake.
42
Recoil Starter
FEATURES AND CONTROLS
2
If the battery has been drained or
damaged and cannot start the
1
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side
of the machine.
1. Position the vehicle on a level
surface and lock the parking
brake (see page 37).
2. Shift the transmission into
neutral.
3. Make sure the engine stop switch is set to RUN and the main key
switch is in the ON position.
NOTE:
If the engine is cold, use the choke as outlined on page 47.
4. Reach under the side panel and grasp the starter rope handle (2)
firmly and pull slowly so you can feel the engine strokes.
NOTE:
Every other stroke will be a “compression stroke” and will
make the rope harder to pull. When a compression stroke is
found, continue pulling the rope just until the engine rolls past
the stroke, then stop pulling immediately.
5. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
6. Repeat steps 4-5 if necessary.
CAUTION
Extending the recoil starter rope until it stops can cause damage
to the recoil assembly. Do not extend the starter rope so far that
it stops.
If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.
43
OPERATION
Break-In Period
The break-in period for your new Polaris ATV is defined as the time it
takes to use the first tank of fuel. No single action on your part is as
important as following the procedures for a proper break-in. Careful
treatment of a new engine will result in more efficient performance and
longer life for the engine. Perform the following procedures carefully.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.
Use of any oils other than those recommended by Polaris may
cause serious engine damage. We recommend the use of
Polaris 2-cycle oil for your 2-cycle engine.
Lack of proper lubrication will cause serious engine damage.
Always fill the oil tank when refueling the ATV.
44
Break-In Period
OPERATION
The first tank of fuel must be pre-mixed according to the following
instructions. After the break-in period, the oil injection system will
provide the necessary engine lubrication without pre-mixing.
1. Premix the recommended oil with gasoline in a suitable gas
container. Refer to the chart below for ratios.
2. Fill the fuel tank (see page 39), then fill the oil tank with the
recommended oil.
3. Drive slowly at first. Vary the throttle positions.
4. Perform regular checks on fluid levels, controls, and areas outlined
on the daily pre-ride inspection checklist on page 46.
After the first tank of pre-mixed fuel has been used, verify that the oil
level in the oil tank has dropped, indicating that the oil pump is
functioning properly. If the level has not dropped, see your dealer for
oil pump bleeding and repeat the pre-mix procedure.
Fuel/Oil Premix Chart
Fuel
Oil @ 40:1
Gallons (Liters)
Ounces (Liters)
1 (3.8)
3.2 (.09)
5 (18.9)
16 (.47)
10 (37.9)
32 (.95)
45
OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury
or death could result. Always inspect the vehicle before each use
to ensure it’s in proper operating condition.
Pre-Ride Checklist
Item
Remarks
See
Page
Brake system / lever travel
Ensure proper operation
36, 75
Brake fluid
Ensure proper level
35
Auxiliary brake
Ensure proper operation
38
Front suspension
Inspect, lubricate if necessary
69
Rear suspension
Inspect, lubricate if necessary
69
Steering
Ensure free operation
Tires
Inspect condition and pressure
82
Wheels / fasteners
Inspect, ensure fastener tightness
81
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
71
Coolant level (if applicable)
Ensure proper level
--
Coolant hoses (if applicable)
Inspect for leaks
Throttle
Ensure proper operation
Indicator lights / switches
Ensure operation
34
Engine stop switch
Ensure proper operation
32
Drive chain
85
Air filter, pre-filter
Check condition / slack, lubricate as
needed
Inspect, clean
Air box sediment tube
Drain deposits whenever visible
Headlamp
Check operation
87
Brake light / tail lamp
Check operation, apply Polaris dielectric grease when lamp is replaced
Wear helmet, goggles, protective
clothing
89
Riding gear
46
--
--
-33, 78
86
--
31
Starting the Engine
OPERATION
Starting a Cold 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.
CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.
1. Place the transmission in neutral and
lock the parking brake. Make sure the
fuel valve is on.
2. Sit on the vehicle and pull the choke
knob (1) out until it stops.
NOTE:
NOTE:
If the knob doesn’t stay where
positioned, increase the tension by
rotating the tension adjusting nut (2)
clockwise.
1
2
The variable choke is fully on when
the knob is pulled completely out.
The choke is off when the knob is
pushed completely in. The choke
can be adjusted gradually, depending on how much choke is
needed for starting. Be sure the choke is off during
operation, as excess fuel washing into the engine oil will
increase wear on engine components.
3. Move the engine stop switch to RUN.
NOTE:
Do not press the throttle while starting the engine.
4. Turn the ignition key past the ON position to engage the starter for
a maximum of five seconds. Release the key when the engine
starts. If it doesn’t start, release the key and wait five seconds.
Activate the starter for another five seconds. Repeat until the
engine starts.
5. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up.
6. Vary the engine RPM slightly with the throttle to aid in warm-up.
When the engine idles smoothly, push the choke all the way in.
47
OPERATION
Starting the Engine
Starting a Warm Engine
Warm engines do not normally require the use of the choke. Excessive
use of the choke can cause the spark plug to become wet fouled.
1. Position the vehicle on a level surface and place the transmission in
neutral.
2. Lock the parking brake, turn the fuel tank valve to ON, sit on the
vehicle, and turn the engine stop switch to RUN.
3. If the engine has cooled to a point where it does not readily start,
intermittent use of the choke (pulled half way out) may be
necessary.
NOTE:
If the engine is over-choked when warm, depress the throttle
lever fully while cranking to aid in starting.
4. Release the throttle lever immediately after the engine starts. If the
engine does not start and all conditions are favorable, change the
spark plug and try again.
48
Driving Safely
OPERATION
Driving Procedures
1. Sit upright with both feet on the footrests and both hands on the
handlebars.
2. Start the engine and allow it to warm up, then shift the transmission
into gear.
3. Check your surroundings and determine your path of travel.
4. Release the parking brake.
5. Slowly depress the throttle with your right thumb and begin driving.
Vehicle speed is controlled by the amount of throttle opening.
6. Drive slowly. Practice maneuvering and using the throttle and brakes
on level surfaces.
49
OPERATION
Driving Safely
Making Turns
Your Polaris ATV is equipped with a solid rear axle that drives both
rear wheels equally at all times. This means that the wheel on the
outside of the turn must travel a greater distance than the inside wheel
when turning and the inside tire must slip traction slightly.
To make a 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.
50
Driving Safely
OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Slow down when entering slippery areas.
2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns which can cause skids.
3. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body weight forward.
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.
51
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow
these precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25_
maximum).
3. Keep both feet on the
footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of
speed and throttle opening.
6. Remain alert and be
25_ Maximum
prepared to take emergency
action. This may include
quick dismounting of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake, gradually. When fully stopped, apply the
auxiliary brake as well, then lock the park brake.
If the ATV begins rolling backwards:
Keep your weight uphill. Never apply engine power. Never apply the
auxiliary rear brake while rolling backwards.
Apply the single-lever brake, gradually. When fully stopped, apply the
auxiliary rear brake as well, and then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described on page 55.
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.
52
Driving Safely
OPERATION
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 a dangerous type of driving and should be avoided if
at all possible. If you do enter into a situation where sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your upper body weight toward the hill
while keeping your feet on the footrests.
3. Steer slightly into the hill to maintain vehicle directions.
NOTE:
If the vehicle begins to tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side
immediately!
53
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing, using the single brake
lever.
NOTE:
Familiarize yourself with operation of the auxiliary rear brake
pedal for additional braking in the event of normal service
brake loss.
WARNING
Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.
54
OPERATION
Driving Safely
Turning Around on a Hill
WARNING
Improper hill climbing procedures 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.
If the vehicle stalls while climbing a hill, never back it down the hill!
One maneuver that can be used when it’s necessary to turn around
while climbing a hill is the K-turn:
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the 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.
6. Lock the parking brake and remount the vehicle from the uphill
side, keeping body weight uphill.
7. Restart the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the brake, until the vehicle is on more level ground.
8’
Uphill
55
OPERATION
Driving Safely
Driving Through Water
1
Your ATV can operate through water with a maximum recommended
depth equal to the bottom of the footrests (1). Follow these procedures
when operating through water:
1. Determine water depths and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 64. The following areas
need special attention: engine oil, transmission oil, front and rear
gearcases and all grease fittings.
56
Driving Safely
OPERATION
Driving Through Water
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 91. Have
the vehicle serviced by your dealer at the first opportunity.
57
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.
58
Driving Safely
OPERATION
Driving in Reverse
Follow these precautions
when operating in reverse:
1. Always avoid backing
downhill.
2. Back slowly.
3. When in reverse,
apply the brakes
lightly for stopping.
4. Avoid turning at sharp
angles in reverse.
5. Never open the throttle
suddenly while backing.
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:
Most Polaris ATVs are equipped with a reverse speed
limiter. The override button should be used with caution as
rearward vehicle speed is greatly increased. Do not operate
at wide open throttle. Open the throttle just enough to
maintain a desired speed.
CAUTION
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
59
OPERATION
Hauling Cargo
2/3
1/3
Your ATV has been designed to carry or tow a certain amount of load
(if equipped with racks). 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.
60
Hauling Cargo
OPERATION
WARNING
Hauling cargo improperly can alter vehicle handling and may
cause loss of control or brake instability and result in serious
injury or death. Always follow these precautions when hauling
cargo:
S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or
hilly terrain, reduce speed and cargo to maintain stable driving
conditions. Carrying loads on one rack only increases the possibility of vehicle overturn.
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS
POSSIBLE. Carrying loads high on the racks raises the center
of gravity of the vehicle and creates a less stable operating
condition. When cargo loads are carried high on the racks, the
weight of the loads must be reduced to maintain stable operating conditions.
S ALL LOADS MUST BE SECURED BEFORE OPERATING.
Unsecured loads can create unstable operating conditions,
which could result in loss of control of the vehicle.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED
LOADS. When handling off-centered loads that cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your
vehicle.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle. Avoid terrain or situations that may require
backing downhill.
S EXTREME CAUTION MUST BE USED when operating with
loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass 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.
61
OPERATION
Driving Safely
Parking on an Incline
Avoid parking on an incline if possible. If it’s unavoidable, follow
these precautions:
1. Turn the engine off.
2. Place the transmission in gear.
3. Set the parking brake.
4. Always block the rear wheels on the downhill side. See
illustration.
5. Shut off the fuel supply.
62
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was tested and approved
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.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES--002.
63
MAINTENANCE AND LUBRICATION
Accessories
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights. See your Polaris dealer.
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.
NOTE:
Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause or see your dealer.
Maintenance Chart Key
"
E
J
Perform these procedures more frequently for vehicles subjected to
severe use.
Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
64
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
J Steering
--
Pre-Ride
--
" Front suspension
--
Pre-Ride
--
" Rear suspension
--
Pre-Ride
--
Tires
Remarks
Make adjustments
j
as needed See Pre
ed.
Pre-Ride
Ride Checklist
on page 46.
--
Pre-Ride
--
" Brake fluid level
--
Pre-Ride
--
" Brake lever travel
--
Pre-Ride
--
Brake system
--
Pre-Ride
--
Wheels/fasteners
--
Pre-Ride
--
Frame fasteners
--
Pre-Ride
--
" Engine oil level
--
Pre-Ride
--
" Air filter, pre-filter
--
Daily
--
Inspect; clean often
" Air box sediment
--
Daily
--
Drain deposits when visible
Headlamp
--
Daily
--
Check operation
Tail light
--
Daily
--
Check operation; apply
dielectric grease if replacing
" Air filter,
--
Weekly
--
Inspect; replace as needed
--
Weekly
--
Drain water as needed,
check often if operating in
wet conditions
10 H
Monthly
100 (160)
Inspect periodically
20 H
Monthly
200 (320)
Check terminals; clean; test
" Transmission oil
25 H
Monthly
250 (400)
Inspect level; change yearly
" Engine breather
25 H
Monthly
250 (400)
Inspect; clean if needed
" General
50 H
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
E
E
E tube
E main element
Recoil housing
" Brake pad wear
J
Battery
E filter (if equipped)
lubrication
65
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item
Carburetor float
bowl
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
50 H
6M
500 (800)
Drain bowl periodically and
prior to storage
J Throttle Cable/
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
J Choke cable
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
50 H
6M
500 (800)
Inspect ducts for proper
sealing/air leaks
50 H
6M
500 (800)
Inspect; adjust; replace as
needed
" Engine oil change
100 H
6M
1000 (1600)
Perform a break-in oil
change at one month
" Oil filter change
100 H
6M
1000 (1600)
Replace with oil change
J Valve clearance
100 H
12 M
1000 (1600)
Inspect; adjust
J Fuel system
100 H
12 M
1000 (1600)
J Fuel filter
100 H
12 M
1000 (1600)
Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
Replace yearly
" Engine mounts
100 H
12 M
1000 (1600)
Inspect
100 H
12 M
1000 (1600)
Inspect
J Spark plug
100 H
12 M
1000 (1600)
Inspect; replace as needed
J Ignition Timing
100 H
12 M
1000 (1600)
Inspect
" Wiring
100 H
12 M
1000 (1600)
J Clutches (drive
100 H
12 M
1000 (1600)
Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Inspect; clean; replace worn
parts
J Front wheel
100 H
12 M
1000 (1600)
E ETC Switch
E
E Carburetor air
intake ducts/
flange
Drive belt
E
E
E
E
E
Exhaust muffler/
pipe
E
E
and driven)
bearings
66
Inspect; replace as needed
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item
J Brake fluid
Spark arrestor
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
Remarks
200 H
24 M
2000 (3200)
Change every two years
300 H
36 M
3000 (4800)
Clean out
E Idle speed
--
Adjust as needed
J Toe adjustment
--
Inspect periodically; adjust
when parts are replaced
--
Adjust as needed
Headlight aim
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
"
67
MAINTENANCE AND LUBRICATION
Periodic Maintenance Record
Use the following chart to record periodic maintenance.
Maintenance
Interval
Performed
10 hrs.
20 hrs.
50 hrs.
100 hrs.
68
Servicing Servicing
Date
Dealer
or Person
Remarks
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 65.
Lubrication Chart Key
"
More often under severe use, such as wet or dusty conditions
L Polaris Premium All Season Grease or grease conforming to NLG
No. 2, such as Conoco Superlube M or Mobilegrease Special
Item
Lube
Method
Engine
Polaris Injection Oil
Fill oil tank. See page 41.
Brakes
DOT 3 fluid only
Maintain level between fill lines. See page
35.
Drive chain(s)
O-ring chain lube or
SAE 80/90
Lubricate as often as required. Before
each ride in wet conditions
Transmission
AGL Synthetic Gearcase Lube
See Page 72.
(1) Ball Joint
"L
Grease
Locate fitting on back side of struts and
grease with grease gun.
(2) Swing Arm
Bushings
"L
Grease
Locate fittings on swing arm and grease
with grease gun.
(3) Axle Housing
"L
Grease
Locate fittings on swing arm and grease
with grease gun.
(2)
(3)
(1)
69
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Polaris 2-Cycle Lubricants
Polaris Premium 2-cycle lubricants are the most advanced formulation
of oils, specifically designed for today’s 2-cycle engines. These
lubricants provide additives for 2-cycle engines that are lacking in
today’s fuel. These necessary additives keep ring grooves cleaner for
less ring sticking and improved overall engine cleanliness.
With new generation lubricity technology, Polaris oils excel in meeting
the lubrication demands of today’s high performance 2-cycle engines.
We recommend the use of these optimum oils for Polaris liquid cooled
or air cooled 2-cycle engines.
Polaris premium 2-cycle oils will mix with each other, but consistent
performance will be enhanced by selecting only one of the premium
oils and maintaining regular use of that oil through the life of the unit.
Your dealer will be able to assist you with that selection, based on your
operating conditions and riding style.
Never mix Polaris premium 2-cycle oils with any other brand of oil,
including Polaris Nature Oil Biodegradable oil. Their incompatibility
could result in engine damage. For best performance, we recommend
that you choose one oil for your ATV, then continue to use it for the
life of the unit.
See page 106 for the part numbers of Polaris products.
Polaris VES II Synthetic 2-Cycle Oil
Your vehicle has been primed with VES II synthetic oil. We
recommend the continued use of this oil for your ATV. This lubricant
has been specially formulated for low smoke, low odor, low deposits
and high lubricity.
Premium 2-Cycle Oil
Polaris also has a TC-W3 premium oil or Premium Gold Synthetic Oil
suitable for use in all of our 2-cycle products.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
2-cycle oils for your 2-cycle engine. Never mix oil brands.
70
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Engine Oil Check
The oil tank cap (1) is located forward
of the headlight. Check the oil before
each use of the vehicle. Refill the oil
when refueling.
1. Position the ATV on a level
surface.
2. Remove the oil tank cap and
inspect the oil level in the tank.
3. Add oil as needed to bring the
level to the full mark. Do not
overfill.
4. Reinstall the oil tank cap.
1
71
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Transmission Oil Check
The transmission oil dipstick (1) is located
1
on the right side of the vehicle. Check and
change the transmission oil at the intervals
outlined in the Periodic Maintenance Chart
beginning on page 65. Maintain the
transmission oil level in the SAFE
operating range (2). We recommend the
use of AGL Synthetic Gearcase Lubricant.
See page 106 for the part numbers of Polaris
products.
2
1. Position the ATV on a level surface.
2. Remove the transmission oil dipstick
and wipe it clean.
3. Reinstall the dipstick, then remove it and read the
oil level. If the level is low, add the recommended gearcase oil to
bring the level within the safe operating range on the dipstick.
4. Reinstall the dipstick.
Transmission Oil Change
A
1. Place a drain pan beneath the
transmission oil drain plug area.
2. Loosen the jam nut (A).
B
3. Turn the adjuster bolt (B) in to
allow the removal of the drain
plug (C).
4. Remove the drain plug and wipe
C
the magnetic end clean to remove
accumulated metallic filings.
5. After the oil has drained
completely, install a new sealing
washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
6. Turn the adjuster bolt (B) out until it touches the frame, and then
turn an additional 1/2 turn.
7. Tighten the jam nut securely while holding the adjuster bolt.
8. Add the recommended lubricant through the dipstick hole until the
oil level is between the upper and lower limits. Do not overfill.
9. Check for leaks.
72
MAINTENANCE AND LUBRICATION
Adjustments
Oil Pump Bleeding
CAUTION
If the oil supply line has been disconnected from the pump, or if
the oil reservoir and supply line have been completely run out of
oil, the oil pump must be bled. If the pump is not bled, air in the
lines may prevent oil delivery to the engine, resulting in severe
engine damage.
1
1. Fill the oil tank with the
recommended oil. See page 106 for
the part numbers of Polaris
products.
2. Loosen the bleeder screw one full
turn. Allow oil to flow from the
bleed screw for five to ten seconds,
then tighten the bleed screw.
2
CAUTION
Allowing the engine to run while the bleed screw is loose will
result in loss of oil, which will cause serious engine damage.
Always retighten the bleed screw if it’s been loosened for service.
3. Start the engine and rotate the oil pump lever (2) to its full open
position. With the engine at idle, hold the lever up for thirty
seconds to purge all air from the system.
73
MAINTENANCE AND LUBRICATION
Adjustments
Oil Pump
If it becomes necessary to increase oil flow into the fuel system, the oil
pump can be adjusted.
1
1. Before adjusting the oil pump, check the
engine idle RPM and carburetor settings
in the specifications section beginning
on page 103.
2. Loosen the throttle cable jam nut and
3
turn the adjuster (1) in or out until there
is 1/16″ - 1/8″ (.16 - .32 cm) of throttle
lever travel before the throttle slide starts
to open.
3. Place very slight pressure on the throttle
lever (2) until all freeplay is removed
2
from the throttle cable (to the point
where the carb slide is just starting to
rise).
4. Loosen the locknut (3).
3
Turn the adjuster in or out
until all freeplay is removed
from the oil pump cable (the
point where the oil pump
arm is just starting to move
off its stop). The pump stop
keeps the pump arm from
rotating any further down
than the idle position so no
visual alignment of marks is
necessary. Tighten the
locknut.
74
MAINTENANCE AND LUBRICATION
Adjustments
Brakes
The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever toward the handlebar. These brakes are
self-adjusting.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation, such as operation in hilly country or in muddy
terrain.
1. Always maintain brake fluid level as
recommended (see page 35).
2. Check the brake system for fluid
leaks.
3. Check the brakes for excessive travel
or spongy feel.
4. Check the friction pads for wear,
damage and looseness.
5. Check the security and surface
condition of the disc.
NOTE:
Install new brake pads when pads
are worn to 3/64″ (.1 cm).
3/64″ (.1 cm)
Auxiliary Brake
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, the rear brake can be
activated by depressing the foot pedal on the inside of the right
footrest.
NOTE:
Since this is a rear brake only, it will not be as effective as
the all-wheel single lever system.
The hydraulic auxiliary brake system requires no adjustment.
Always maintain the brake fluid level as recommended. See page 38.
75
MAINTENANCE AND LUBRICATION
Adjustments
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.
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ to 1/4″ toe out.
1. Set the handlebars in a
straight-ahead position.
NOTE:
The steering frog can be
used as an indicator of
whether the handlebars
are straight. The frog
should always point
straight back from the
steering post.
2
2. Place stands (1) in front of
the vehicle, perpendicular to
the rear tires. See
illustration.
3
3. Tie an elastic string around
the stands, making sure the
string just touches the side
surface of the rear tires on
each side of the vehicle and
goes around the stands in
front of the vehicle (2).
1
4. Measure the distance from
the string to the rim at the
front and rear of the front
rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm)
more than the front measurement.
NOTE:
76
If you discover improper alignment, see your Polaris dealer
for service.
MAINTENANCE AND LUBRICATION
Adjustments
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.
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is adjusted
by rotating the adjuster (1) either
clockwise or counterclockwise to increase
or decrease spring tension.
NOTE:
1
Accessory springs are available
through your Polaris dealer.
77
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.
Handlebars
1
The handlebars can be adjusted for
rider preference.
1. Remove the handlebar cover
and locate handlebar bolts (1).
2. Loosen the four bolts.
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the
gas tank or any other part of the
machine when turned fully to the left or right.
4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque
the rear two bolts. A gap of up to 1/8” will remain at the rear
bolts.
Throttle Cable Freeplay
Throttle cable freeplay is adjusted at the handlebar.
1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).
2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
thumb lever.
NOTE:
While adjusting freeplay, be sure to flip the throttle lever back
and forth.
3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the midpoint of the adjuster.
1
78
2
3
1
MAINTENANCE AND LUBRICATION
Adjustments
Carburetor
IMPORTANT: Your Polaris ATV is calibrated at the factory for
optimal performance at altitudes ranging from zero to 6,000 feet (1800
m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and
the engine loses approximately 3% of its power for each 1000-foot
(304.8 m) increase in elevation. Although this power cannot be
regained, adjustments to the carburetor and drive system can be made
to allow more efficient operation. Optional jets, available from your
Polaris dealer, are required for operation above 6,000 feet and
temperatures below +40 degrees F. (4 degrees C.)
NOTE:
Continuous operation of the engine without proper jetting
when required can cause poor performance, overheating or
engine damage. See your Polaris dealer for more information
about jetting the ATV for conditions in your area.
If the engine idle speed is not satisfactory, and all other conditions are
favorable, the carburetor can be adjusted.
1. Warm up the engine by running the
vehicle for approximately five
minutes.
2. Place the transmission in gear and lock
the parking brake.
1
3. Adjust the carburetor idle screw (1)
either in or out until the desired idle
RPM is reached. Turn the screw in
(clockwise) to raise RPM. Turn the
screw out (counterclockwise) to
2
lower RPM.
The following variations apply to air screw (2) adjustment for 2-cycle
engines:
S For improving cold weather start and reducing audible detonation
noise, the air screw can be closed from 1/2 to 1 turn by turning the
screw clockwise.
S During hot weather and/or high altitude operation the air screw can
be adjusted for smoother operation by turning the screw counterclockwise for approximately 2 turns.
79
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Operating your ATV with worn tires, improperly inflated tires,
non-standard tires or improperly installed tires will affect vehicle
handling 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 your 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 cm)
or less.
Wheel Removal
1. Stop the engine, place the transmission in gear and lock the
parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
4. Remove the wheel nuts and remove the wheel.
80
MAINTENANCE AND LUBRICATION
Adjustments
Wheel Installation
1. Place the transmission in gear and lock the parking brake.
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.
2. Place the wheel on the wheel hub with the valve stem toward the
outside and the rotation arrows on the tire pointing toward forward
rotation.
3. Install the wheel nuts and finger tighten. On vehicles with tapered
rear wheel nuts, make sure the tapered ends of the nuts fit into the
tapers on the wheels.
4. Lower the vehicle to the ground.
5. Torque the wheel nuts according to the wheel nut torque
specifications chart.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.
Item
Specification
Front Wheel Nuts
27 ft. lbs. (36.5 Nm)
Rear Wheel Nuts
50 ft. lbs. (68 Nm)
Front
Rear
50 ft. lbs.
(68 Nm)
27 ft. lbs.
(36.5 Nm)
81
MAINTENANCE AND LUBRICATION
Adjustments
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.
Tire Tread Depth
Always replace tires when tread
depth is worn to 1/8″ (.3 cm) or less.
See illustration.
1/8I (.3 cm)
WARNING
Operating the vehicle with worn tires will increase the possibility
of skidding, which could lead to loss of control and serious injury
or death. Always replace tires when the tread depth measures
1/8″ (.3 cm) or less.
WARNING
Use of non-standard size or type of tires or improper tire inflation
may adversely affect vehicle maneuverability and cause loss of
control resulting in serious injury or death. Maintain proper tire
pressure as outlined in this owner’s manual. When replacing a
tire always use original equipment size and type.
82
MAINTENANCE AND LUBRICATION
Adjustments
Drive Chain
Polaris ATV drive chains are equipped with o-ring-sealed, permanently
greased pins and rollers. However, the outer surfaces of the roller must
be lubricated.
1. Always inspect the drive chain prior to operating the vehicle.
Check for damaged or missing o-rings or damaged rollers.
2. Check for correct slack adjustment.
3. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).
4. Regularly lubricate the drive chain with Polaris chain lube or SAE
80-90 lube. See page 106 for the part numbers of Polaris products.
CAUTION
Washing the drive chain with a high pressure washer or gasoline
can cause damage to the o-rings, causing premature wear and
drive chain failure. Don’t use a high pressure washer or gasoline
to clean the drive chain.
Cylinder Head/Cylinder Base Fastener
Have your dealer check the ATV cylinder head and cylinder base
fasteners for proper torque at the first service or after 25 hours.
83
MAINTENANCE AND LUBRICATION
Adjustments
Rear Drive Chain Slack
CAUTION
Adjusting or operating the ATV with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Check the amount of chain slack in three different locations by moving
the vehicle slightly forward. Measure the chain slack at the tightest of
the three positions. At this point the chain should have 3/16″-3/8″ (.48
cm - .95 cm) deflection. Use the following procedure if adjustment is
required.
1
3/16″-3/8″ (.48 cm - .95 cm)
1. Loosen the chain guide.
2. Loosen the two eccentric
locking bolts (1).
3. Loosen the caliper mounting
bolt located on the left side
of the swing arm.
4. Insert a pin punch (2)
through the sprocket hub
and into the eccentric
housing.
84
2
1
MAINTENANCE AND LUBRICATION
Adjustments
Rear Drive Chain Slack
1. Roll the ATV forward or backward
to adjust the chain slack to the
proper tension. See the illustration
for proper splice link clip opening
position (1).
2. Tighten the eccentric locking bolts
to 30 ft. lbs. (41 Nm) for machines
1
without the hitch and 45 ft. lbs. (61
Nm) for machines with a hitch.
3. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm).
4. Remove the pin punch.
5. Roll the ATV forward, checking chain tension in several places
around the chain.
NOTE:
The chain is adjusted correctly when the tightest portion of
the chain has approximately 3/8” (10mm) deflection.
6. Position the chain guide to allow 1/8” (3mm) clearance and tighten
the retaining bolt to 5 ft. lbs. (7 Nm).
7. Reinstall the chain guard if applicable.
85
MAINTENANCE AND LUBRICATION
Filter Systems
Air Filter Removal and Service
1.
2.
3.
4.
5.
6.
Remove the ATV seat.
Release the clips securing the cover assembly to the air box.
Loosen the clamp securing the filter, and remove the filter.
Remove the foam pre-filter from the main filter.
Wash the pre-filter in soapy water, then rinse and let dry.
Re-install the pre-filter over the main filter. (Replace the main filter
if needed.)
Air Filter Installation
1. Check the condition of the air box and replace if necessary.
2. Replace the filter over the carburetor boot. Make sure the filter is
fully seated in the air box.
3. Tighten the clamp. Do not overtighten, as filter damage could
occur.
4. Check the cover gasket and replace if needed. Be sure the cover is
seated properly, then snap the clips onto the cover.
5. Reinstall the ATV seat.
Air Filter Cleaning
Check and replace the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 65.
NOTE:
Always replace the main filter when it becomes dirty. In an
emergency situation, however, you may clean the main filter
if you observe the following practices.
1. Never immerse the main filter in water. Dirt can be transferred to
the clean air side of the filter.
2. If compressed air is used for cleaning, never exceed a pressure of
40 PSI. Always use a dispersion-type nozzle to prevent filter
damage, and blow the air from the inside to the outside.
86
Lights
MAINTENANCE AND LUBRICATION
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. Do not service
the headlamps until they’ve cooled sufficiently.
Headlight Lamp Replacement
1. Remove the front cover and unplug the light harness.
2. Remove the rubber cap from the back of the headlight to reveal the
retention screw.
3. Remove the small phillips head screw, and carefully remove the
bulb from the housing.
4. Insert the new bulb into the housing and reinstall the retention
screw. Reinstall the rubber cap.
5. Reconnect the light harness and reinstall the cover.
6. Adjust the headlight aim if necessary.
87
MAINTENANCE AND LUBRICATION
Lights
Headlight Adjustment
1
1. Position the vehicle on
a level surface with the
headlight approximately
25 ft. (7.6 m) from a
flat wall.
2. Measure the distance
1
from the floor to the
center of the headlight
and make a mark on the
wall at the same height.
3. Start the engine and
turn on the headlight.
4. Observe the headlight
aim on the wall. The most intense part of the headlight beam
should be aimed 8” (20.3 cm) below the mark placed on the wall.
NOTE:
Include rider weight on the seat when measuring.
5. Adjust the beam to the desired position by turning the adjustment
screws (1):
S Turning the right screw clockwise moves the intense spot of light up
and to the left.
S Turning the left screw clockwise moves the intense spot of the light
up and to the right.
S Turning the bottom screw clockwise adjusts the light upward.
88
Lights
MAINTENANCE AND LUBRICATION
Taillight/Brakelight Lamp Replacement
If the taillight/brakelight does not work the lamp may need to be
replaced.
1. Remove the taillight lens cover
mounting screws. Remove the
lens cover and gasket and set
aside for reassembly.
2. Remove the lamp (1). Apply
dielectric grease to the socket
and install the new lamp.
3. Test the taillight/brakelight to
see that it’s working.
1
4. Reinstall the gasket and lens cover.
Indicator Lamp Replacement
1. Remove the instrument panel, if necessary, to access the back of
the indicator panel.
2. Using a small, straight-blade screwdriver, turn the base of the bulb
1/4 turn counterclockwise.
3. Using a needle-nose plier or similar tool, pull the lamp out of the
indicator panel housing.
4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.
5. Reassemble the pod or front cover.
89
MAINTENANCE AND LUBRICATION
Spark Plugs
Always use the spark plugs recommended for your ATV. Refer to the
specifications section beginning on page 103 for the recommended spark
plug type and gap.
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. Normal
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 white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect carburetion adjustments.
2. Wet Fouled
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 injection oil, improper use of the choke, or
incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove.
3. Reverse the procedure for spark plug installation. Torque to 14 ft.
lbs. (19 Nm).
90
MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry land or at the
very least, to water below the foot
rests.
2. Check the airbox for any water. Drain
and dry it if water is present.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Remove the bowl drain (1).
6. Remove the crankcase drain screw at
the left front of the engine bottom.
7. Turn the engine over several times
using the electric start.
8. Dry the spark plug and reinstall, or replace it with a new plug.
9. Reinstall the bowl drain.
10. Reinstall the crankcase drain screw.
11. Turn the fuel valve on.
12. Attempt to start the engine. If necessary, repeat the drying
procedure.
13. Take the ATV to your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE:
1
If water has been ingested into the PVT, follow the procedure
on page 95 for drying out the PVT.
91
MAINTENANCE AND LUBRICATION
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.
Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.
Remove any combustible materials from the area. Wear eye
protection and leather work gloves. Do not stand behind or in
front of the vehicle while purging. Never run the engine in an
enclosed area. Exhaust contains poisonous carbon monoxide
gas. Never go under the vehicle while it’s inclined.
1. Remove the arrestor clean-out
plug (1) from the bottom of the
muffler.
2. Place the transmission in neutral
and start the engine.
3. Purge carbon from the system by
1
momentarily revving the engine
several times.
4. If carbon is expelled, cover or plug the
exhaust outlet (2) and rap on the pipe around
the cleanout plug while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Set the parking brake
and block the wheels. Make sure the vehicle is in neutral and
repeat steps 3 and 4 until no more particles are expelled when the
engine is revved.
6. Stop the engine and allow the arrestor to cool. Reinstall the
arrestor plug and remove the outlet cover or plug.
92
MAINTENANCE AND LUBRICATION
Recoil Housing
1
To prevent possible engine damage,
always drain the recoil housing (1)
after operating the ATV in very wet
conditions. This should also be
done before storing the ATV.
Water will enter the recoil housing
if the starter handle is disengaged
from the rope guide when under
water. The recoil handle must be
behind the heat shield for it to seal
properly.
The drain screw is located at the bottom of the recoil housing. Use a
wrench to remove the screw. Be sure to reinstall the screw after
draining the housing.
93
MAINTENANCE AND LUBRICATION
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of “pinch” applied to the
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt “pinch.” This
begins to occur at speeds of less than 5 MPH, due to the system’s
dependence on engine speed.
For example, when operating at a ground speed of 3 MPH, the engine
would be running at only about 1500 RPM, with an engagement speed
of about 1400 RPM. Whenever operating this close to the engagement
point, the engine may be running at a speed too low to provide the
adequate “pinch” needed to prevent incomplete engagement.
Incomplete engagement creates excessive heat that can destroy belts
and clutch covers. In some cases, excessive clutch wear and damage
may result.
If the ATV will be operated for extended periods below 5 MPH, or for
towing loads, we recommend that you install a one tooth smaller
counter shaft sprocket to raise the operating RPM far enough above the
engagement RPM to reduce heat caused by incomplete engagement.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).
NOTE:
94
Avoid heavy pulling and extended low-speed
operation.
MAINTENANCE AND LUBRICATION
PVT System
WARNING
Failure to comply with the instructions in this warning can result in
severe injury or death.
Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.
PVT Drying
There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Replace the
drain plug.
2. Start the engine and shift the transmission into neutral. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.
95
MAINTENANCE AND LUBRICATION
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.
Disconnect the battery hold-down strap and remove the battery cover.
Disconnect the black (negative) battery cable first.
Disconnect the red (positive) battery cable next.
Lift the battery out of the ATV.
Battery Installation
When installing a new battery, make sure it’s fully charged prior to its
initial use. 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
97 before installing the battery.
1. Ensure that the battery is fully charged.
2. Set the battery in the battery holder.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Reinstall the battery cover and attach the hold-down strap.
6. Verify that cables are properly routed.
96
Battery
MAINTENANCE AND LUBRICATION
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:
Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a
month to make up for normal self-discharge. Battery
Tendert can be left connected during the storage period,
and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
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. Do not ever 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.
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 the 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 following guidelines for
recharging.
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.
97
MAINTENANCE AND LUBRICATION
Battery
Battery Charging
NOTE:
Always verify battery condition before and 1-2 hours after the
end of charging.
State of
Charge
Voltage
100%
12.8-13.0 volts
None, check at
3 mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75%
12.0-12.5 volts
Needs charge
5-11 hours
25%-50%
11.5-12.0 volts
Needs charge
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less
Needs charge with
desulfating charger
At least 20 hours
98
Action
Charge Time*
(Using constant current
charger @ standard amps
specified on top of battery)
MAINTENANCE AND LUBRICATION
Cleaning and Storage
See page 106 for the part numbers of Polaris products.
Cleaning the ATV
Keeping your ATV clean will not only improve its appearance but it
can also extend the life of various components. With a few
precautions, your ATV can be cleaned much like an automobile.
Washing the ATV
The best and safest way to clean your ATV is with a garden hose and a
pail of mild soap and water. Use a professional type washing mitten,
cleaning the upper body first and the lower parts last. Rinse with water
frequently and dry with a chamois to prevent water spots.
NOTE:
If warning and safety labels are damaged, contact your a
Polaris dealer for free replacement.
Polaris does not recommend the use of a high pressure type car wash
system for washing the ATV. If a high pressure system is used,
exercise extreme care to avoid water damage to the wheel bearings,
transmission seals, body panels, brakes, warning labels and decals.
NOTE:
Grease all zerk fittings immediately after washing, and allow
the vehicle to run for a while to evaporate any water that may
have entered the engine or exhaust system.
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax.
Avoid the use of harsh cleaners since they can scratch the body finish.
CAUTION
Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Use caution when using these products
near plastic surfaces.
99
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 106 for the part numbers of Polaris products.
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.
Exterior
Make necessary repairs and then clean the ATV thoroughly with mild
soap and warm water to remove all dirt and grime. Don’t use harsh
detergents or high pressure washers. Some detergents deteriorate rubber
parts. Use dish soap type cleaners only. High pressure washers may
force water past seals.
Fuel Stabilizer
Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It
cleans the fuel system, the combustion chamber and the exhaust ports.
It also prevents bacterial growth and promotes better starting after the
storage period.
1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel
Stabilizer. Follow the instructions on the container for the
recommended amounts.
2. Start the engine and allow it to run for 15-20 minutes so the stabilizer
can disperse through the fuel in the tank and carburetor.
3. Stop the engine, turn the fuel valve off, and drain the carburetor bowl.
Air Filter / Air Box
Inspect and clean or replace the pre-cleaner and air filter. Clean the air
box and drain the sediment tube.
Recoil Housing
Remove the recoil housing drain plug and drain any moisture.
Fluid Levels
Inspect the following fluid levels and change if necessary: engine oil;
transmission oil; brake fluid (change every two years or as needed if
fluid looks dark or contaminated).
100
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 106 for the part numbers of Polaris products.
Engine
Use Polaris Fogging Oil and follow the directions on the can.
If you choose not to use Polaris Fogging Oil, perform the following
procedure.
1. Support the front end of the machine so the engine is level or tilted
slightly rearward.
2. Remove the spark plug. Rotate the piston to BDC and pour
approximately two ounces of the recommended oil into the
cylinder. Reinstall the spark plug.
3. Apply dielectric grease to the inside of the spark plug cap and install
the cap onto the plug.
4. With the ignition off, turn the engine over several times using the
recoil starter. This will ensure coverage of the piston rings,
cylinder walls and crankshaft bearings.
5. Treat the fuel system with Polaris Carbon Clean.
6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
carburetor should be completely drained of gasoline.
Lubricate
Inspect all cables and lubricate with Polaris Cable Lubricant. Follow
lubrication guidelines in the maintenance section of the service or
owner’s manual to completely grease and lubricate the entire vehicle
with Polaris Premium All Season Grease. Apply Polaris O-Ring Chain
Lube to the drive chain.
Battery Storage
Remove the battery from the vehicle and ensure that it’s fully charged
before placing it in storage. See page 97 for instructions.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires 1-2” off
the ground. Be sure the storage area is well ventilated, and cover the
machine with a genuine Polaris ATV cover.
NOTE:
Do not use plastic or coated materials. They do not allow
enough ventilation to prevent condensation, and may promote
corrosion and oxidation.
101
MAINTENANCE AND LUBRICATION
Cleaning and Storage
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.
1. Wash chrome rims frequently. Use a mild detergent to remove any
salt, dirt, mud or grime. Never use abrasive cleaners on plated or
painted surfaces.
2. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
3. 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.
4. 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.
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.
Transporting an ATV
Follow these procedures when
transporting an ATV.
1. Turn off the engine and remove the
key to prevent loss during
transporting.
2. Turn the fuel valve off.
3. Be sure the fuel cap, oil cap and seat
are installed correctly and securely.
4. Always tie the frame of the ATV to
the transporting unit securely using
suitable straps or rope. The rack,
bumper or handlebars do not offer
enough support for tie-down while
transporting the unit.
5. Always place the transmission in gear
and lock the parking brake.
102
2005 Trail Blazer
Body Style
Gross Vehicle Weight
Fuel Capacity
Engine Oil
Transmission Oil
Front Rack (Accessory)
(Maximum Capacity)
Rear Rack (Accessory)
Tongue Weight
Tow Hitch
Tow Capacity
Turn Radius
Ground Clearance
Height
Length
Seat Height
Dry Weight
Wheel Base
Width
Engine Model Number / Type
Lubrication
Bore x Stroke
Displacement
Compression Ratio
Engine Cooling
Alternator Output
Carburetion
Main Jet
Pilot Jet
Needle Jet
Pilot Screw
Jet Needle
Ignition
Timing
Spark Plug Type / Gap
SPECIFICATIONS
Capacities
Gen III
765 lbs. (347 kg)
3.5 U.S. gal. (13.2 l)
2 qts. (1.89 l)
11.3 oz. (.33 l)
30 lbs. (13.6 kg)
60 lbs. (27.2 kg)
85 lbs. (38.5 kg)
Accessory
850 lbs. (385.5 kg)
63 in. (160 cm)
5.5 (14 cm)
47 in. (119.4 cm)
75 in. (190.5 cm)
34 in. (86.4 cm)
461 lbs. (209.1 kg)
48 in. (121.9 cm)
46 in. (116.8 cm)
Engine & Cooling
EC-25PFE-154 / 2 Cycle, Single Cylinder
Oil Injection
72 x 60
244cc
6.1/1 Effective
Air
150 watts @ 4000 RPM
1/VM30SS
130 (hex)
40
0-4 (169)
1.0
5DP7-3
CDI
25° ± 3° @ 3000
NGK BR8ES / .028 in. (.7 mm)
103
SPECIFICATIONS
2005 Trail Blazer
Drive System Type
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - Forward
Front Drive (ratio)
Final Drive (ratio)
Center Drive (ratio)
Drive Chain
Front Tire
Rear Tire
Front Suspension
Rear Suspension
Shock Adjustment
Front Brake
Rear Brake
Auxiliary Brake
Park Brake
Headlight
Taillight
Brake Light
Battery
DC Plug-In (Rear)
DC Socket (Forward)
Electric Start
High Temp Indicator
Windshield
Low Oil Light
Neutral Indicator
Reverse Indicator
Speedometer
Fuel Gauge
Tool Kit
104
Drive System
PVT
Side Lever (F-N-R)
Not Applicable
3.05/1
2.68/1
Not Applicable
11/36 76P
Not Applicable
520 O-Ring
23 x 7-10 (4 psi)
22 x 11-10 (3 psi)
Suspension and Brakes
McPherson Strut w/8.2″ (20.8 cm) travel
Progressive Rate w/10.5″ (26.7 cm) travel
CAM
Hydraulic Disc
Hydraulic Disc
Hydraulic Disc
Hydraulic lock, all wheel
Features
1 Single Beam (55 w)
8.26 w
26.9 w
12V 14 AH
Accessory
Accessory
Standard
Not Available
Accessory
Standard
Standard
Standard
Accessory
Standard
Standard
SPECIFICATIONS
2005 Trail Blazer
Jetting Chart
Altitude
Ambient
Temperature
Below 0°F
(Below --18°C)
0° to 40°F
(--18°C to
+5°C)
+40° to +80°F
(+5°C to
+26°C)
+80°F & Above
(+26°C &
Above)
Meters
(Feet)
0-900
(0-3000)
150
140
130
120
900-1800
(3000-6000)
140
130
120
110
1800-2700
(6000-9000)
125
120
110
100
2700-3700
(9000-12000)
115
110
100
95
Turn air screw out 1/2 turn CCW from seat. Raise needle clip 1 position to lower jet needle.
Clutching Chart
Altitude
Meters
(Feet)
Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Helix/Spring
Setting
0-1800
(0-6000)
G
(5630514)
Blue/Green
(7041157)
Red
(7041198)
40°
(5131446)
2+2
1800-3700
(6000-12000)
F
(5630515)
Blue/Green
(7041157)
Red
(7041198)
40°
(5131446)
2+2
105
POLARIS PRODUCTS
Part No.
Description
2870791
2871098
2871097
2871721
2871722
Engine Lubricant
Fogging Oil (12 oz. Aerosol)
Premium Blue 2-Cycle Mineral Oil (qt.)
Premium Blue 2-Cycle Mineral Oil (gal.)
Premium Gold Synthetic 2-Cycle Oil (qt.)
Premium Gold Synthetic 2-Cycle Oil (gal.)
2874438
VES II Synthetic 2-Cycle Oil (qt.)
2874439
VES II Synthetic 2-Cycle Oil (gal.)
2873602
2873603
2870465
Gearcase / Transmission Lubricants
Premium AGL Synthetic Gearcase Lube (qt.)
Premium AGL Synthetic Gearcase Lube (gal.)
Pump for Gallon Jug
2871322
2871423
2871460
2871312
2871329
2872073
2872348
Grease / Specialized Lubricants
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Starter Drive Grease
Grease Gun Kit
Dielectric Grease (Nyogelt)
Chain Lube (6.25 oz. aerosol)
Chain Lube (16 oz. aerosol)
2872889
2871326
2870652
2870990
2872893
Additives / Miscellaneous
Brake and Clutch Cleaner
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT3 Brake Fluid
Engine Degreaser
106
TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause
Solution
Driving the ATV onto a
pickup or tall trailer in
high range.
Avoid stopping on the ramp or creeping slowly up the
ramp. These practices may slip the clutch and belt.
Starting out going up a
steep incline.
When starting out on an incline, use low range or dismount the ATV (after first applying the park brake) and
perform the K-turn as described on page 55.
Driving at low RPM or
Drive at a higher speed. Avoid creeping.
low ground speed (at
approximately 3-7 MPH).
Insufficient warm-up of
Warm the engine at least 5 minutes. With the transmission
ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in
bient temperatures.
short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow and easy clutch engagement.
Use the throttle quickly and effectively for efficient engagement.
Towing/pushing at low
RPM/low ground speed.
Install a one tooth smaller counter shaft sprocket.
Stuck in mud or snow.
Carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Climbing over large objects from a stopped position.
Carefully use fast, brief, aggressive throttle application to
engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Belt slippage from water
Dry out the PVT as outlined on page 95. Inspect clutch
or snow ingestion into the seals for damage if repeated leaking occurs.
PVT system.
Clutch malfunction.
Contact your Polaris dealer for inspection of clutch components.
Poor engine performance. Check for fouled plugs or foreign material in gas tank,
fuel lines, or carburetor. Contact your dealer for service.
107
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Doesn’t Turn Over
Possible Cause
Solution
Low battery voltage
Recharge battery to 12.8 VDC
Loose battery connections
Check all connections and tighten
Loose solenoid connections
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Solution
Out of fuel
Turn fuel valve to reserve, refuel
Clogged fuel valve or filter
Inspect and clean or replace
Water is present in fuel
Drain the fuel system and refuel
Fuel valve is turned off
Turn the fuel valve on
Old or non-recommended fuel
Replace with new fuel
Fouled or defective spark plug(s)
Inspect plug(s), replace if necessary
No spark to spark plug
Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel
Immediately see your Polaris dealer
Overuse of choke
Inspect, clean and/or replace spark plugs
Clogged fuel filter
Replace the filter
Low battery voltage
Recharge battery to 12.8 VDC
Mechanical failure
See your Polaris dealer
Engine Pings or Knocks
Possible Cause
Solution
Poor quality or low octane fuel
Replace with recommended fuel
Incorrect ignition timing
See your Polaris dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
108
TROUBLESHOOTING
Engine Backfires
Possible Cause
Solution
Weak spark from spark plugs
Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Old or non-recommended fuel
Replace with new fuel
Incorrectly installed spark plug wires
See your Polaris dealer
Incorrect ignition timing
See your Polaris dealer
Mechanical failure
See your Polaris dealer
Engine Runs Irregularly, Stalls or Misfires
Possible Weak Spark Cause
Solution
Fouled or defective spark plugs
Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires
See your Polaris dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Loose ignition connections
Check all connections and tighten
Water present in fuel
Replace with new fuel
Low battery voltage
Recharge battery to 12.8 VDC
Kinked or plugged fuel vent line
Inspect and replace
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your Polaris dealer
Electronic throttle control malfunction
See your Polaris dealer
Other mechanical failure
See your Polaris dealer
Possible Lean Fuel Mixture Cause
Solution
Low or contaminated fuel
Add or change fuel, clean the fuel system
Low octane fuel
Replace with recommended fuel
Clogged fuel filter
Replace filter
Incorrect jetting
See your Polaris dealer
Possible Rich Fuel Mixture Cause
Solution
Overuse of choke
Inspect, clean and/or replace spark plugs
Fuel is very high octane
Replace with lower octane fuel
Incorrect jetting
See your Polaris dealer
109
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Solution
Out of fuel
Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line
Inspect and replace
Water present in fuel
Replace with new fuel
Overuse of choke
Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs
Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires
See your Polaris dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Loose ignition connections
Check all connections and tighten
Low battery voltage
Recharge battery to 12.8 VDC
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your Polaris dealer
Electronic throttle control malfunction
See your Polaris dealer
Other mechanical failure
See your Polaris dealer
Overheated engine
Clean engine exterior
See your Polaris dealer
110
LIMITED WARRANTY
WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED
WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects
in material or workmanship. Polaris also gives a one year limited warranty on the final drive
chain for failure due to defects. This warranty covers the parts and labor charges for repair
or replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. This warranty is transferrable 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. THE PURCHASER MUST COMPLETE AN ATV SAFETY
TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID
WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser
as the copy of the Warranty Registration Form will be the warranty entitlement. If you have
not signed the original registration and received the “customer copy”, please contact your
dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS
YOUR ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free
operation. Purchasing a machine in the crate or without proper dealer set-up will void your
warranty coverage.
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.
111
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT
STATED IN THIS WARRANTY. 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 personnel 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.
2. Damage resulting from the use of non-recommended lubricants may not be covered by
warranty.
112
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.
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
113
INDEX
A
F
Accessories . . . . . . . . . . . . . . . . . . . 64
Adjustments . . . . . . . . . . . . . . . . 73-85
Age Restrictions . . . . . . . . . . . . . . . . 8
Air Filter . . . . . . . . . . . . . . . . . . . . . 86
Auxiliary Brake . . . . . . . . . . . . 38, 75
FEATURES . . . . . . . . . . . . . . . . 32-43
Filter Systems . . . . . . . . . . . . . . . . . 86
Front Wheel Hub Tightening . . . . . 82
Fuel Filter . . . . . . . . . . . . . . . . . . . . 39
Fuel Safety . . . . . . . . . . . . . . . . . . . 40
Fuel Stabilizer . . . . . . . . . . . . . . . . 100
Fuel Tank . . . . . . . . . . . . . . . . . . . . 39
Fuel Valve . . . . . . . . . . . . . . . . . . . . 39
B
Battery . . . . . . . . . . . . . . . . . . . . 96-98
Battery Charging . . . . . . . . . . . . . 97-98
Battery Installation . . . . . . . . . . . . . 96
Battery Removal . . . . . . . . . . . . . . . 96
Battery Storage . . . . . . . . . . . . 97, 102
Brake Lever . . . . . . . . . . . . . . . . . . 36
Brakes . . . . . . . . . . . . . . . . . . . . 35, 75
Break-In Period . . . . . . . . . . . . . . 44-45
C
Camber and Caster . . . . . . . . . . . . . 77
Carburetor . . . . . . . . . . . . . . . . . . . . 79
Choke . . . . . . . . . . . . . . . . . . . . . . . 39
Chrome Wheel Care . . . . . . . . . . . 102
Cleaning and Storage . . . . . . . . 99-102
Cleaning the ATV . . . . . . . . . . . . . . 99
Clutching Chart . . . . . . . . . . . . . . . 105
CONTROLS . . . . . . . . . . . . . . . . 32-43
Corrosion, Removing . . . . . . . . . . 102
Cylinder Head/
Cylinder Base Fastener . . . . . . 83
G
Gear Selector . . . . . . . . . . . . . . . . . . 42
H
Handlebars . . . . . . . . . . . . . . . . . . . 78
Hauling Cargo . . . . . . . . . . . . . . . 60-61
Headlight Adjustment . . . . . . . . . . . 88
Headlight Lamp Replacement . . . . . 87
I
Indicator Lamp Replacement . . . . . 89
Indicator Lights . . . . . . . . . . . . . . . . 34
J
Jetting Chart . . . . . . . . . . . . . . . . . 105
K
K-Turn . . . . . . . . . . . . . . . . . . . . . . 55
D
L
Drive Chain . . . . . . . . . . . . . . . . . . 83
Driving Downhill . . . . . . . . . . . . . . 54
Driving in Reverse . . . . . . . . . . . . . 59
Driving on Slippery Surfaces . . . . . 51
Driving Over Obstacles . . . . . . . . . . 58
Driving Procedures . . . . . . . . . . . . . 49
Driving Safely . . . . . . . . . . . . . . . 49-62
Driving Through Water . . . . . . . . 56-57
Driving Uphill . . . . . . . . . . . . . . . . 52
Light Switches . . . . . . . . . . . . . . . . 34
Lights . . . . . . . . . . . . . . . . . . . . . 87-89
Lubricants, 2-Cycle . . . . . . . . . . . . . 70
Lubrication Recommendations . . 69-72
E
Electrical Switches . . . . . . . . . . . . .
EMISSION CONTROL SYSTEMS
Engine Fogging . . . . . . . . . . . . . .
Engine Oil Check . . . . . . . . . . . . . .
Equipment Modifications . . . . . . . .
114
32
63
101
71
12
M
Main Switch . . . . . . . . . . . . . . . . . . 32
MAINTENANCE AND
LUBRICATION . . . . . . . . 64-102
Maintenance Record . . . . . . . . . . . . 68
Making Turns . . . . . . . . . . . . . . . . . 50
N
Noise Emission Control System . . . 63
INDEX
O
T
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil Injection Tank . . . . . . . . . . . . . . 41
Oil Pump Adjustment . . . . . . . . . . . 74
Oil Pump Bleeding . . . . . . . . . . . . . 73
OPERATION . . . . . . . . . . . . . . . 44-62
Operator Safety . . . . . . . . . . . . . . . 8-27
Override Switch . . . . . . . . . . . . . . . 32
TABLE OF CONTENTS . . . . . . . . . 5
Taillight/Brakelight
Lamp Replacement . . . . . . . . . 89
Throttle Cable Freeplay . . . . . . . . . . 78
Throttle Lever . . . . . . . . . . . . . . . . . 33
Tire Tread Depth . . . . . . . . . . . . . . . 82
Toe Alignment . . . . . . . . . . . . . . . . 76
Transmission Gear Selector . . . . . . . 42
Transmission Oil Change . . . . . . . . 72
Transmission Oil Check . . . . . . . . . 72
Transporting an ATV . . . . . . . . . . 102
TROUBLESHOOTING . . . . . 107-110
Turning Around on a Hill . . . . . . . . 55
P
Parking Brake . . . . . . . . . . . . . . . . . 37
Parking on an Incline . . . . . . . . . . . 62
Periodic Maintenance Chart . . . . 64-67
POLARIS PRODUCTS . . . . . . . . 106
Pre-Ride Inspection . . . . . . . . . . . . . 46
PVT Drying . . . . . . . . . . . . . . . . . . 95
PVT System . . . . . . . . . . . . . . . . 94-95
U
USFS Approved Spark Arrestor . . . 63
R
V
Rear Drive Chain Slack . . . . . . . . 84-85
Rear Spring . . . . . . . . . . . . . . . . . . . 77
Recoil Housing . . . . . . . . . . . . . . . . 93
Recoil Starter . . . . . . . . . . . . . . . . . 43
VEHICLE IDENTIFICATION
NUMBERS . . . . . . . . . . . . . . . . 7
Vehicle Immersion . . . . . . . . . . . . . 91
S
WARRANTY . . . . . . . . . . . . . 111-113
Washing the ATV . . . . . . . . . . . . . . 99
Waxing the ATV . . . . . . . . . . . . . . . 99
WELCOME . . . . . . . . . . . . . . . . . . . 3
Wheel Installation . . . . . . . . . . . . . . 81
Wheel Nut Torque Specifications . . 81
Wheel Removal . . . . . . . . . . . . . . . 80
Safe Riding Gear . . . . . . . . . . . . . . . 31
SAFETY . . . . . . . . . . . . . . . . . . . . 8-31
Safety Decals and Locations . . . . 28-30
Safety Training . . . . . . . . . . . . . . . . . 8
Sidehilling . . . . . . . . . . . . . . . . . . . 53
Spark Arrestor . . . . . . . . . . . . . . . . . 92
Spark Plugs . . . . . . . . . . . . . . . . . . . 90
SPECIFICATIONS . . . . . . . . . 103-105
Starting a Cold Engine . . . . . . . . . . 47
Starting a Warm Engine . . . . . . . . . 48
Starting the Engine . . . . . . . . . . . 47-48
Steering Assembly . . . . . . . . . . . . . 77
Stop Switch . . . . . . . . . . . . . . . . . . . 32
Storage Tips . . . . . . . . . . . . . . 100-102
W
115