ATV 200 Owner`s manual

PMS 419
Phoenix 200
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
Adult supervision is required for children under 16 years of age.
Operation is prohibited for children under 14 years of age.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
A card containing important ATV safety information should be
attached to the owner's manual on the next page. If you cannot
locate this card, or if it has been removed, please call 1-800342-3764 for assistance.
Dear Parents:
We believe your children should have the opportunity to enjoy the
POLARIS riding experience along with you. We've provided this
owner's manual to assist you and your children in learning about
safe operation and care of your new ATV.
A POLARIS ATV is not a toy and can be hazardous to operate.
Make sure any child who will operate the ATV takes a training
course before operating the ATV. Make sure all operators understand and follow all of the instructions and warnings contained in
this owner’s manual. Help them also learn to show respect for our
environment and for the rights of others while operting the ATV.
Never allow a child under the age of 16 to operate an ATV without
adult supervision. Children differ in skills, physical abilities and
judgement. Some children may not be able to operate an ATV
safely. Permit continued use only if you determine that your child
has the ability and maturity to operate the ATV safely.
For your child’s safety, be sure your child can reach and operate
all ATV controls, including handlebars, brake levers, throttle
lever and engine stop switch.
The preventive maintenance program outlined in this manual is
designed to ensure that all critical components on your child's
ATV are thoroughly inspected at specific intervals. Follow all of
the instructions and recommendations in this manual.
Dear Children:
Before you ride your new Polaris ATV, there are some
important things that you need to know. You must learn
how to keep yourself and those around you safe while
you're riding. Your parents and Polaris want you to enjoy
riding your new ATV, and that's why you need to read
and understand the information in your owner's manual.
You must also take an ATV training course before you
begin riding.
Ask your parents to explain anything you don't
understand, and pay close attention to the warnings and
instructions you read. Your safety and the safety of
others is the most important thing to think about at all
times. Never drive your ATV alone. Always make sure
an adult is watching you when you ride.
Drive safely and enjoy riding your new Polaris ATV!
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• RZR® sport vehicles
• VICTORY® motorcycles
• GEM® 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.
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.
1
POLARIS® is a registered trademark of POLARIS Industries Inc.
Copyright 2013 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in Taiwan
2014 Phoenix 200 Owner’s Manual
P/N 9924651
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 93
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 96
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . 98
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 106
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a certified ATV safety
training course (www.atvsafety.org).
• For your child’s safety, be sure your child can reach and operate all ATV
controls, including handlebars, brake levers, throttle lever and engine stop
switch.
• Adult supervision is required for children under age 16.
• NEVER allow anyone under 14 years of age to operate this vehicle.
• 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 (www.atvsafety.org).
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
5
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
VIN
Engine Serial Number
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
6
SAFETY
Safety Training
ATV safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding the ATV to
take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer
provided information about the authorized ATV RiderCoursesm that is
available to you and your eligible family members. This training is
included in the purchase price of your ATV. 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 in the United States, you can
enroll in the ATV RiderCoursesm for a fee. Call ATV Enrollment Express
at (800) 887-2887 or visit www.atvsafety.org.
If you purchased a POLARIS ATV outside the United States, please
contact your dealer or local law enforcement agencies for information
about safety training.
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
FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
POLARIS at 1-800-342-3764.
7
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Eye Protection
Long
Sleeves
Helmet
Gloves
Long Pants
Boots
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
051039
distinguishing number of the country which has
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding a POLARIS vehicle, always wear shatterproof goggles
or use a shatterproof helmet face shield. POLARIS recommends
wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye
wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-ankle boots with low
heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best
protection.
Equipment Modifications
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.
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.
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.
9
SAFETY
Safety Warnings
WARNING
Failure to operate the ATV properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
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.
Age Restrictions
This vehicle is for recreational use by adults or
young operators under adult supervision.
Adult supervision is required for children under
age 16.
NEVER permit children under age 14 to operate
this ATV.
10
UNDER
14
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
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.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
11
SAFETY
Safety Warnings
Protective Apparel
Operating this ATV without wearing an
approved helmet increases the risk of a
serious head injury in the event of an
accident.
Always wear 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.
Using Alcohol or Drugs
Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
rollover.
Never carry a passenger on this ATV.
12
SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or rollover.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.
13
SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or rollover.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
rollover.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or rollover. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 41.
14
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or rollover.
• 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 43.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or rollover. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 42.
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 44.
15
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause a
rollover.
• Always maintain a steady speed when climbing
a hill.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the front brakes (right lever).
• When fully stopped, apply the rear brake as well,
and then lock the parking brake.
• Lock the parking brake when fully stopped.
• 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 44.
If the ATV begins rolling downhill:
• Keep body weight uphill.
• Apply the front brakes gradually.
• Never apply the rear brake while rolling backwards.
• Never apply engine power.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 44.
Operating on Steep Hills
Operating on excessively steep hills could cause a
rollover.
Never operate on hills too steep for the ATV or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.
16
SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this ATV with improper tires or with improper or uneven tire pressure
could cause loss of control or accident.
Always use the size and type of tires specified for your ATV.
Always maintain proper tire pressure as described in the owner's manual and on
safety labels.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
rollover.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control
or rollover.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be alert
to changing terrain conditions.
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 47.
Before shifting into reverse gear, always check for obstacles or people behind
the ATV. When it's safe to proceed, back slowly.
Operating on Slippery Terrain
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain
could cause loss of traction, loss of control,
accident or rollover.
Do not operate on excessively rough, slippery
or loose terrain. Always use extra caution on
rough, slippery or loose terrain.
17
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or rollover.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 46.
Skidding or Sliding
Skidding or sliding can cause loss of control or rollover (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.
Operating Through Deep Water
Operating the ATV through deep or fastflowing water could cause the tires to float,
causing loss of control or rollover.
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
45):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward
motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water.
18
SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.
• 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.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any rollover or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
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 rollover and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or rollover. Always remove the ignition key
when the vehicle is not in use.
19
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
20
SAFETY
Safety Labels and Locations
Discretionary
Warning
+
General
Warning
Discretionary Warning
WARNING
• Never operate this ATV on HILLS steeper than 25 degrees
25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
7175511
21
SAFETY
Safety Labels and Locations
“No Passenger”
Warning
Tire Pressure/Load
Warning
Age
Warning
Clutch Cover
Warning
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
7175378
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 4.0 psi (27.6 kPa)
Rear: 4.0 psi (27.6 kPa)
• Maximum weight capacity: 215 lbs. (98 kg)
7175445
22
SAFETY
Safety Labels and Locations
Age Warning
WARNING
Operation of this ATV by children under the age of 14 increases the risk of
severe injury or death.
Adult supervision is required for children under age 16.
NEVER permit children under age 14 to operate this ATV.
Clutch Cover Warning
WARNING
• 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
7173313
23
FEATURES AND CONTROLS
Switches
Override
Switch
Light
Switch
ON
OFF
Main Key
Switch
Start
Button
Engine
Stop Switch
Light Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
to operate the headlights.
Engine Stop Switch
Before starting the engine, press the upper end of the switch down to the
ON position. To stop the engine, press the lower end of the switch down
to the OFF position. The engine will not start or run when the switch is
off.
Main Key Switch
Turn the main key switch clockwise to the ON position before starting
the engine. Turn the main switch off to stop the engine and end all electrical power to the vehicle.
Start Button
To start the engine, make sure the stop switch is in the ON position.
Turn the main key switch on. Press the start button.
24
FEATURES AND CONTROLS
Switches
Override Switch (Reverse Speed Limiter)
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override switch.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
Throttle Lever
WARNING
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
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.
Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.
Engine speed and vehicle movement
are controlled by pressing the throttle lever. The throttle lever is spring
loaded. Engine speed returns to idle
when the lever is released.
This ATV is equipped with
POLARIS Electronic Throttle Control (ETC), which is designed to
reduce the risk of a frozen or stuck throttle. If the throttle cable should
stick in an open position when the operator releases the throttle lever,
the engine will stop, and power to the rear wheels will cease.
25
FEATURES AND CONTROLS
Brakes
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. Always contact your dealer for service before operating the vehicle.
WARNING
Aggressively applying the rear brakes when backing down a hill may cause rear
tipover, which could result in serious injury or death. Never back down a hill.
Use caution when applying the rear brakes. Do not aggressively apply the rear
brakes when going forward. The rear wheels may skid and slide sideways,
causing loss of control, which may result in serious injury or death.
Front Brakes (Right Lever)
Squeeze the right brake lever toward
Front Brakes
the handlebar to apply the hydraulic
front wheel brakes. This lever does not
apply the rear brakes.
Always test front 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.
26
FEATURES AND CONTROLS
Brakes
Rear Brakes (Left Lever)
Rear Brakes
Squeeze the left brake lever toward the
handlebar to apply the mechanical rear
wheel brakes. This lever does not
apply the front brakes.
Rear Brakes (Foot Brake)
The foot brake operates the rear
brakes. The foot brake is located on
the inside of the right footrest. Operate
this brake with your right foot. The
foot brake is a mechanical rear wheel
brake.
If the rear wheels slide while using the
foot brake, reduce brake pedal pressure to brake the rear wheels without
skidding.
Foot Brake
27
FEATURES AND CONTROLS
Brakes
Parking Brake
1. Place the transmission in
gear.
2. Squeeze and release the left
brake lever two or three
times, then squeeze and hold.
3. Push the parking brake lock
down to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.
28
FEATURES AND CONTROLS
Brakes
Brake Fluid
WARNING
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
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 brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid level in the
Indicator
master cylinder before each ride.
Window
Always maintain brake fluid at the
Master
recommended level.
Cylinder
The master cylinder is located on
the left handlebar. Maintain the
fluid level 1/4" (6.3 mm) below the
top edge of the master cylinder. Do
not overfill.
1. Position the vehicle on a level
surface. Make sure the handlebars are straight.
2. View the fluid level through the
indicator window (eye) on the
top of the master cylinder. The
eye will appear dark when the
fluid level is full. When fluid is low, the eye will be clear.
3. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
Tip: Under normal operation, the diaphragm extends into the reservoir as fluid
level drops. If the fluid level is low and the diaphragm is not extended, a
leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is
loosened or removed. Do not overfill.
29
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 36 for correct choke and throttle settings during starting.
Fuel Tank Cap
Fuel Tank Cap
Always refuel with the engine
Fuel Valve
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.
Use POLARIS Carbon Clean fuel
treatment at each fill. Follow the
mixing directions on the container.
See page 98 for the part numbers of
POLARIS products.
Use either leaded or unleaded gasoline with a minimum pump octane
number of 87=(R+ M/2) octane.
Non-ethanol fuel is recommended. Do not use fuel with ethanol content
greater than 10 percent, such as E-85 fuel.
Fuel Valve
The fuel valve is located on
the left side of the vehicle.
ON: For normal operation.
OFF: For vehicle storage
and when transporting.
RES: Turn the valve to the
OFF
ON
RES
reserve setting if the main
fuel supply is exhausted.
Refuel as soon as possible. Return the valve to the ON position after
refueling.
Reserve fuel range is about 7-10 miles (11-16 km).
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100
hours of operation or annually. Do not attempt to clean the fuel filter.
30
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is located
on the right side of the vehicle.
F: Forward Gear
N: Neutral
R: Reverse
To shift gears, brake to a complete stop.
When the engine is idling, move the
lever to the desired gear.
Gear
Selector
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in
gear and lock the parking brake.
Indicator Lights
Indicator lights on the handlebar
console illuminate when neutral
or reverse gears are selected.
The neutral indicator is green.
The reverse indicator is amber.
Neutral
Reverse
Kick-Start Lever
If the battery is too weak to start the engine, use the kick-start lever to
start the engine until the battery is serviced.
1. Position the vehicle on a level surface. Lock the parking brake.
Place the transmission in neutral.
2. Fold out the kick-start lever on the left side of the ATV.
3. Make sure the stop switch and main key switch are on.
4. Place your foot on the kick-start. Thrust your heel downward to
crank the engine.
5. If the engine is cold, use the choke as outlined on page 36.
6. After the engine has started, fold the kick-start lever back into place.
Tip: A 10/12 mm wrench is provided in the tool kit for removing or installing the
lever. If not installed, make sure the rubber cap is installed on the kick-start
shaft to protect the rider. Store the kick-start lever under the seat in the rear
cab when not installed.
31
OPERATION
WARNING
Failure to operate the ATV properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first ten hours
of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and
drive components will result in more efficient performance and longer
life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 30. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level. See page 57. Add oil as needed to maintain the
level in the proper range.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 35.
6. Pull only light loads (if equipped with a hitch).
7. Change both the oil and the filter at 20 hours, 200 miles or one
month, whichever comes first.
32
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle. See page 7.
2. Do not allow anyone under 14 years of age to operate this vehicle.
Adult supervision is required for children under age 16. Do not
allow anyone with cognitive or physical disabilities to operate this
vehicle.
3. Never carry a passenger on this ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
8. Never consume alcohol or drugs before or while operating an ATV.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged ATV. After any rollover or accident, have
a qualified service dealer inspect the entire machine for possible
damage.
11. Never operate the ATV on a frozen body of water.
12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
33
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
34
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.
Item
Remarks
Page
Brake system/lever travel
Ensure proper operation
26
62
Brake fluid
Ensure proper level
29
Foot brake
Ensure proper operation
27
Front suspension
Inspect, lubricate if necessary
56
Rear suspension
Inspect, lubricate if necessary
56
Steering
Ensure free operation
Tires
Inspect condition and pressure
66
Wheels/fasteners
Inspect, ensure fastener tightness
66
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
30
57
Coolant level (if applicable)
Ensure proper level
-
Coolant hoses (if applicable)
Inspect for leaks
-
Throttle
Ensure proper operation
25
92
Indicator lights/switches
Ensure operation
24
Engine stop switch
Ensure proper operation
24
Air filter, pre-filter
Inspect, clean
68
Air box sediment tube
Drain deposits whenever visible
Headlight
Check operation, apply POLARIS
dielectric grease when lamp is
replaced
24
69
Brake light/tail lamp
Check operation, apply POLARIS
dielectric grease when lamp is
replaced
69
Riding gear
Wear approved helmet, goggles, and
protective clothing
8
-
-
-
35
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-ventilated area.
2. Place the transmission in neutral.
3. Lock the parking brake.
4. Turn the fuel valve on.
5. Sit on the vehicle.
Tip: Do not use the choke if starting a warm engine.
Excessive use of the choke can cause the spark
plug to become wet fouled.
6. If the engine is cold, move the choke lever
to the left until it stops.
Tip: The choke is fully on when the lever is completely to the left. The choke is off when the
lever is completely to the right. The choke can
be adjusted gradually, depending on how much
choke is needed for starting.
7. Place the engine stop switch in the ON
position, then turn the main key switch on.
8. Do not press the throttle while starting the
engine. Squeeze the left brake lever.
Choke
Lever
Tip: The starter will not engage unless the rear brake is applied. Always
squeeze and hold the left brake lever before attempting to start the engine.
9. Press the start button.
36
OPERATION
Starting the Engine
10. Activate the starter for a maximum of five seconds, releasing the
button when the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
11. If the engine does not start, release the start button, wait five seconds, then attempt to start again. Repeat this procedure until the
engine starts.
12. If the engine slows or stops, move the choke lever half way to the
right to allow proper engine warm-up. Vary the engine RPM
slightly with the throttle to aid in warm-up.
13. When the engine idles smoothly, move the choke lever completely
to the right.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained.
Tip: Water accumulation increases as outside temperature decreases.
If the oil level rises to the top of the sight glass, change the oil immediately. Always operate the engine long enough to reach operating temperature, which reduces condensation.
37
OPERATION
Driving Procedures
1. Wear a helmet and eye protection. See page 8.
2. Sit upright with both feet on the footrests and both hands on the
handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the left brake lever and slowly depress the throttle with your
right thumb to begin driving.
7. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
38
OPERATION
Turning the Vehicle
To turn, steer in the direction of the turn, leaning your upper body to the
inside of the turn while supporting your weight on the outer footrest.
The same leaning technique should be used for turning in reverse.
Practice making turns at slow speeds before attempting to turn at faster
speeds.
WARNING! Turning improperly can result in vehicle rollover. Never turn
abruptly or at sharp angles. Never turn at high speeds.
39
OPERATION
Driving on Slippery Surfaces
Sideways
skid
Turn in
direction of
skid
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
4. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
40
OPERATION
Driving Uphill
25° Maximum
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. Whenever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25° maximum).
3. Always check the terrain carefully before ascending any hill.
4. Never climb hills with excessively slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift body weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
8. Never go over the top of a hill at high speed.
9. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
41
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or rollover. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Shift body weight uphill.
4. Keep your feet on the footrests.
5. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
42
OPERATION
Driving Downhill
25° Maximum
When driving downhill, follow these precautions:
1. Avoid steep hills (25° maximum).
2. Shift body weight uphill.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling downhill can cause
loss of control.
5. Squeeze the rear (left) brake lever gradually. Applying the brakes
too firmly may cause the rear wheels to lock, which could result in
loss of control.
43
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
1.
1.
2.
3.
4.
5.
6.
7.
8.
44
Squeeze the front (right) brake lever to stop the vehicle.
Lock the parking brake while keeping body weight uphill.
Leave the transmission in forward and shut off the engine.
Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
Staying uphill of the vehicle, turn the handlebars full left.
While holding the rear (left) 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.
Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
Start the engine with the transmission still in forward.
Release the parking brake and proceed slowly. Control speed with
the rear brake until the vehicle is on more level ground.
OPERATION
Driving Through Water
Your ATV can operate
through water with a maximum recommended depth
equal to the bottom of the
footrests. Follow these procedures when operating
through water:
1. Determine water
depths and current
before entering water.
2. Choose a crossing
where both banks have
gradual inclines.
3. Avoid operating
through deep or fastflowing water.
Maximum Depth
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 52. The following areas need
special attention: engine oil, transmission oil, rear gearcase oil, and
all grease fittings.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 72,
then see your dealer for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.
45
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.
46
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.
NOTICE: 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.
47
OPERATION
Hauling Cargo
WARNING
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
CARRY LOAD AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on
the rack raises the center of gravity of the vehicle and creates a less stable
operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing vehicle
rollover.
NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) while towing a load on a level surface.
Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads in rough
terrain, while cornering, or while ascending or descending a hill.
48
OPERATION
Hauling Cargo
Maximum
70 lbs. (31.7 kg)
Never exceed the weight capacities specified for your ATV on warning
labels and in the specifications section of this manual. Always read and
understand the load distribution warnings listed on the accessory rack
and hitch warning labels.
Never carry cargo on the front of the vehicle. If the accessory rear rack
is installed, cargo should be evenly distributed and mounted as low as
possible on the rack.
Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
When operating over rough or hilly terrain, reduce speed and cargo or
towed load to maintain stable driving conditions.
49
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
50
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified
to be in accordance with the USFS standard 5100-1c. Federal law
requires that this spark arrester be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine and
related components must be maintained at POLARIS specifications to
achieve optimal performance.
Engine idle speed is the only adjustment POLARIS recommends that
the operator perform. Any other adjustments should be performed by an
authorized POLARIS dealer.
The vehicle compliance labels can be found on the frame tubing of the
vehicle.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.
51
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log beginning on
page 106.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles
per hour (16 km/h). Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
52
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
Symbol
Description
Ź
Perform these operations more often for vehicles subjected to severe use.
E
Emission-related service (failure to conduct this maintenance will not void
the emissions warranty but may affect emissions)
D
Have an authorized POLARIS dealer perform these services.
WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer perform these services.
53
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Steering
-
-
Front suspension
-
-
Rear suspension
-
-
Tires
-
Brake fluid level
-
Brake lever travel
-
Brake system
-
-
Wheels/fasteners
-
-
Pre-Ride
-
Inspect and make
adjustments as needed.
See Pre-Ride Checklist on
page 35.
Frame fasteners
-
-
Engine oil level
-
-
Fuel Tank
-
Daily
-
Add Carbon Clean with each
fuel fill. See page 30.
Ź Air filter, pre-filter
E
-
Daily
-
Inspect; clean often; replace
as needed
Ź Air box sediment
tube
-
Daily
-
Drain deposits when visible
Headlamp/tail
lamp
-
Daily
-
Check operation; apply
dielectric grease if replacing
Ź Air filter,
E main element
-
Weekly
-
Inspect; replace as needed
10 H
Monthly
100 (160)
Ź Brake pad wear
D
Battery
Inspect periodically
20 H
Monthly
200 (320)
Check terminals; clean; test
Ź Engine oil change
20 H
1M
250 (400)
Break-in oil and filter change
Ź Front gearcase oil
(if equipped)
25 H
1M
250 (400)
Break-in oil level check
Ź Transmission oil
25 H
1M
250 (400)
Break-in oil level check
Ź Engine breather
E filter (if equipped)
25 H
Monthly
250 (400)
Inspect; clean if needed
Ź General
lubrication
50 H
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
50 H
6M
500 (800)
Drain bowl periodically and
prior to storage
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
Carburetor float
bowl
D Throttle Cable/
E ETC Switch
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
54
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
D Choke cable
E
50 H
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary
E Carburetor air
intake ducts/flange
50 H
6M
500 (800
Inspect duct for proper sealing/air leaks
50 H
6M
500 (800)
Inspect; adjust; replace as
needed
Ź Engine oil change
100 H
6M
Ź Oil filter change
100 H
6M
1000 (1600) Replace with oil change
Ź Front gearcase oil
(if equipped)
100 H
12 M
1000 (1600) Change fluid
Ź Transmission oil
100 H
12 M
1000 (1600) Change fluid
D Valve clearance
E
100 H
12 M
1000 (1600) Inspect; adjust
D Fuel system/filter
E
100 H
12 M
1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
Ź Engine mounts
100 H
12 M
1000 (1600) Inspect
100 H
12 M
1000 (1600) Inspect
D Spark plug
E
100 H
12 M
1000 (1600) Inspect; replace as needed
D Ignition Timing
E
100 H
12 M
1000 (1600) Inspect
Ź Wiring
100 H
12 M
1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H
12 M
1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H
12 M
1000 (1600) Inspect; replace as needed
D Brake fluid
200 H
24 M
2000 (3200) Change every two years
300 H
36 M
3000 (4800) Clean out
Drive belt
Exhaust muffler/
pipe
Spark arrester
Idle speed
D Toe adjustment
Headlight aim
1000 (1600) Perform a break-in oil change
at 20 hours
-
Adjust as needed
-
Inspect periodically; adjust
when parts are replaced
-
Adjust as needed
55
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Items not listed in the
chart should be lubricated at the General Lubrication interval.
Item
Lube
Method
Engine Oil
PS-4 Extreme Duty
10W-50 4-Cycle Oil
See page 57.
Brake Fluid
DOT 4 Brake Fluid
See page 29.
Transmission Oil
AGL Gearcase Lubricant
& Transmission Fluid
See page 60.
Rear Gearcase
ATV Angle Drive Fluid
See page 61.
Front A-Arms
U-Joint Grease
Inspect; tighten fasteners; grease
(also after washing ATV or driving
in water)
Front A-Arms
56
MAINTENANCE
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 52. POLARIS recommends the use of POLARIS PS-4 Extreme Duty 10W-50 4-cycle engine
oil for this vehicle. Oil may need to be changed more frequently if
POLARIS oil is not used. Follow the manufacturer's recommendations
for ambient temperature operation.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
Oil Specifications
Lubricant
PS-4 Extreme Duty
10W-50 4-Cycle Oil
Capacity
41 oz. (1200 ml)
Drain Plug Torque
11 ft. lbs. (15 Nm)
Oil Level
Maintain the oil level at the center of the sight glass. Do not overfill.
NOTICE: A rising oil level between checks in cool weather driving can indicate
contaminants such as gas or moisture collecting in the crankcase. If
the oil level rises to the top of the sight glass, change the oil
immediately.
1. Position the vehicle on a
level surface.
2. View the oil level through
the sight glass on the right
side of the vehicle.
3. Remove the fill plug and
add the recommended oil
as needed.
4. Reinstall the fill plug
securely.
Fill Plug
Sight Glass
57
MAINTENANCE
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 52. Always change the oil filter
whenever changing oil.
NOTICE: If the ATV is left without oil in the system for extended periods, the oil
pump may lose its prime, which could result in engine damage.
Always replace the oil and filter within a few hours of draining the oil.
Do not allow the vehicle to be without oil overnight.
1. Obtain the correct oil filter and an adequate supply of oil so the oil
and filter change can be completed without interruption.
2. Position the vehicle on a level surface.
3. Clean the area around the drain plug on the bottom of the engine
crankcase.
4. Run the engine for two to three minutes until warm. Stop the engine.
5. Place a drain pan beneath the engine crankcase and remove the
drain plug. Allow the oil to drain completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
6. Install a new sealing washer on the drain plug. The sealing surfaces
on the drain plug and crankcase should be clean and free of burrs,
nicks or scratches.
7. Reinstall the drain plug. Torque to specification.
58
MAINTENANCE
Oil and Filter Change
8. Place towels under the oil filter. Using an oil filter wrench,
turn the filter counterclockwise to remove it.
9. Using a clean, dry cloth, clean
the filter sealing surface on
the crankcase.
10. Lubricate the gasket on the
new filter with a film of
engine oil. Check to make
sure the gasket is in good condition.
11. Install the new filter and turn
by hand until the filter gasket
contacts the sealing surface,
then turn and additional 1/2
turn.
12. Remove the oil fill plug and add the recommended oil. Do not overfill.
13. Reinstall the fill plug.
14. Start the engine and let it idle for one to two minutes.
15. Stop the engine and inspect for leaks.
16. Check the oil level and add oil as necessary to maintain the level at
the center of the sight glass.
17. Discard used oil and filter properly.
59
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 52. Maintain the
oil level between 1/4 and 3/4 on the sight glass. See page 98 for the part
numbers of POLARIS products.
Transmission Oil Recommendations
Gearcase
Lubricant
Capacity
Drain Plug Torque
Transmission
AGL Gearcase Lubricant &
Transmission Fluid
18.6 oz.
(550 ml)
18 ft. lbs.
(24 Nm)
Oil Check
1. Position the vehicle on a
level surface.
2. View the oil level
through the sight glass.
3. Remove the fill plug and
add the recommended
oil as needed.
4. Reinstall the fill plug.
Fill Plug
Sight Glass
Oil Change
The transmission drain plug
is located on the bottom of the vehicle near the center.
1. Remove the fill plug.
2. Remove the transmission drain plug. Drain the oil into an appropriate container. Discard used oil properly.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the recommended fluid.
5. Reinstall the fill plug.
6. Check for leaks.
60
MAINTENANCE
Rear Gearcase Oil
Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 52.
Maintain the oil level at the bottom of the check plug hole. We recommend the use of POLARIS ATV Angle Drive Fluid. Use of other oils
may result in improper operation of components. See page 98 for the
part numbers of POLARIS products.
Rear Gearcase Oil Recommendations
Gearcase
Lubricant
Capacity
Fill Plug
Torque
Drain/Check Plug
Torque
Rear
Gearcase
ATV Angle Drive
Fluid
4 oz.
(120 ml)
25 ft. lbs.
(34 Nm)
18 ft. lbs.
(24 Nm)
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the check plug and view
the oil level.
3. Remove the fill plug. Add the
recommended oil as needed.
4. Reinstall the fill plug. Torque to
specification.
5. Reinstall the check plug. Torque to
specification.
6. Check for leaks.
Oil Change
Fill Plug
Check Plug
1. Remove the skid plate.
2. Remove the drain plug. Drain the oil into an appropriate container.
Discard used oil properly.
3. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
4. Remove the fill plug and add the recommended gearcase oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the skid plate.
61
MAINTENANCE
Brakes
Front Brake Inspections
The front (right lever) brakes are hydraulic disc brakes, activated by
moving the brake lever toward the handlebar. This brake system is selfadjusting.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an
adequate level. See page 29.
2. Check the brake system for
fluid leaks.
3. Check the brakes for excessive
travel or spongy feel.
4. Check the friction pads for
wear, damage and looseness.
Replace the pads when the friction material is worn to 1 mm.
5. Check the security and surface
1 mm
condition of the disc.
62
MAINTENANCE
Brakes
Rear Brake Adjustments
The rear (left lever) brakes
2 1/2" (65 mm)
are mechanical brakes, activated by moving the brake
lever toward the handlebar.
The foot brake is also a
mechanical rear brake.
Adjust the rear brakes when brake lever travel reaches 2 1/2" (65 mm).
Always adjust the brakes when there is no longer sufficient stopping
ability at the specified lever travel setting.
1. Position the vehicle on a level surface.
2. Block the front wheels.
3. Place the transmission in neutral.
4. Using suitable stands, elevate the rear of the vehicle so the rear
wheels are slightly off the ground.
5. Slowly tighten the hand
Foot Brake
Hand Brake
brake wing nut while
Wing Nut
Wing Nut
rotating the rear wheels
with your hand. When
you begin to feel resistance (drag) in the wheel
rotation, loosen the wing
nut one full turn.
6. Slowly tighten the foot
brake wing nut until the
foot brake lever arm
begins to move. Loosen
the wing nut 1/2 turn so it
doesn't influence the hand
brake adjustment.
7. Test the hand brake and
the foot brake for proper
operation.
63
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8 to 1/4 inch (3-6 mm) toe out.
WARNING! Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a
level surface.
2. Set the handlebars in a
straight-ahead position
and secure them in this
position.
3. Place a chalk mark on the
2
center line of the front
tires approximately 10
inches (25.4 cm) from the
1
floor, or as close to the
hub/axle center line as
possible. Make sure both
marks are the same distance from the floor.
4. Measure the distance between the marks and record the
measurement (1).
5. Move the vehicle until the chalk marks are at the rear of the tires,
even with the hub/axle center line.
6. Measure the distance between the marks and record the
measurement (2).
7. Subtract measurement 2 from measurement 1. The difference is the
vehicle toe-out alignment.
8. If you discover improper alignment, see your POLARIS dealer for
service.
64
MAINTENANCE
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
Side Panel Removal
1. Remove the seat.
2. Remove the three fasteners
securing the side panel to
the vehicle.
3. Pull the side panel away
from the vehicle.
Fasteners
65
MAINTENANCE
Tires
WARNING
Operating your ATV with worn tires, improperly inflated tires, non-standard tires
or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 96 for recommended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm) or
less.
1/8" (3 mm)
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized
POLARIS dealer.
66
MAINTENANCE
Tires
Wheel Removal
1.
2.
3.
4.
Position the vehicle on a level surface.
Place the transmission in gear.
Stop the engine. Lock the parking brake.
Loosen the wheel nuts slightly.
WARNING! Do not service axle nuts that have a cotter pin installed. See your
POLARIS dealer.
5. Place a suitable stand under the footrest frame to raise the wheel
slightly off the ground.
6. Remove the wheel nuts. Remove the wheel.
Wheel Installation
1. 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.
2. Install the wheel nuts finger tight.
3. Lower the vehicle to the ground.
4. Torque the wheel nuts to specification.
WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or rollover. Always ensure that all nuts are torqued to
specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loosened for service.
Location
Nut Torque
Front Wheel
27 ft. lbs. (37 Nm)
Rear Wheel
27 ft. lbs. (37 Nm)
67
MAINTENANCE
Air Filter
1. Position the vehicle on a
level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. Remove the seat.
5. Release the air box cover
clips, and remove the air box
cover.
6. Loosen the clamp and
remove the air filter.
7. Remove the pre-filter from the main filter.
8. Wash the pre-filter in soapy water, then rinse and let dry.
9. Reinstall the pre-filter over the main filter. Replace the main filter if
needed.
10. Reinstall the air filter into the air box. Tighten the clamp, but do not
over-tighten as filter damage could occur.
11. Reinstall the air box cover and the seat.
68
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.
Headlamp Replacement
To access the assembly from the front, remove the front cover and
unplug the wiring harness. Remove the headlight assembly from the
vehicle.
To access the headlight assembly without removing the front cover,
reach up under the front cab.
1. Remove the rubber cover
Rubber
from the back of the headCover
light.
2. Rotate the socket counterclockwise and pull it away
from the headlight assembly.
3. Remove the headlamp and
install the new headlamp.
Socket
4. Reinstall all components.
Taillight/Brakelight Lamp Replacement
1.
2.
3.
4.
5.
6.
Remove the taillight lens cover mounting screws.
Remove the lens cover.
Remove the lamp.
Apply dielectric grease to the socket and install a new lamp.
Test the light for proper operation.
Reinstall the lens cover.
69
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 96 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.
Plug Condition
Torque Specification
New Spark Plug
9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug
17-20 ft. lbs. (23-27 Nm)
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 71.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
1. Remove the spark plug
cap.
2. Using the special wrench
provided in the tool
pouch, rotate the spark
plug counterclockwise to
remove it.
3. Reverse the procedure
for spark plug
installation. Torque to
specification.
70
Spark Plug Cap
MAINTENANCE
Spark Plugs
Spark Plug Condition
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil, improper use of the choke, or incorrect throttle body/carburetor adjustments.
71
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine.
If it's impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry land or at the
very least, to water below the footrests.
2. Turn the fuel valve off.
3. Check the air box and dry any water.
4. Remove the spark plug.
5. Loosen the carburetor drain screw
and drain the carburetor.
6. Turn the engine over several times
using the electric start.
7. Dry the spark plug. Reinstall the
plug or install a new plug.
8. Tighten the carburetor drain screw.
Drain
9. Turn the fuel valve on.
Screw
10. Attempt to start the engine. If necessary, repeat the drying procedure.
11. Take the ATV to your dealer for service as soon as possible, whether
you succeed in starting it or not.
12. If water has been ingested into the transmission, follow the procedure on page 74 for drying.
72
MAINTENANCE
Spark Arrester
WARNING
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death. Never run the engine in an enclosed area.
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 go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrester while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to
periodically remove accumulated
carbon from the arrester screen.
1. Remove the three screws and
remove the arrester from the end of
the muffler.
2. Use a non-synthetic brush to clean
the arrester screen. A synthetic
brush may melt if components are
warm. If necessary, blow debris
from the screen with compressed
air.
3. Inspect the screen for wear and
damage. Replace if necessary.
4. Remove and inspect the gasket.
Replace a worn or damaged gasket.
5. Reinstall the gasket and arrester.
6. Torque screws to 50 in. lbs. (5.6 Nm).
Screws
73
MAINTENANCE
Constant Variable Transmission (CVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the CVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The CVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The CVT 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 CVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the CVT housing is securely in place during operation.
CVT Drying
There may be some instances when water is accidently ingested into the
CVT system. Use the following instructions to dry it out before operating.
1. Remove the CVT drain plug from the bottom of the CVT cover.
2. Allow the water to drain completely. Reinstall the drain plug.
3. Start the engine. Place the transmission in neutral.
4. 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.
5. Allow the engine RPM to settle to idle speed, then shift the transmission into forward gear.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
74
MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its
flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow
cleaning solution or tap water into a conventional battery.
75
MAINTENANCE
Battery
Battery Removal
1. Remove the seat.
2. Disconnect the battery
hold-down strap.
3. On conventional batteries,
remove the battery vent
tube.
4. Disconnect the black
(negative) battery cable
first.
5. Disconnect the red
(positive) battery cable
last.
6. Lift the battery out of the battery compartment. Be careful not to tip
a conventional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
76
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 79 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Secure the battery hold-down strap.
8. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
9. Reinstall the seat.
77
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 98 for the part
numbers of POLARIS products.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
Battery Fluid (Conventional Battery)
A poorly maintained battery
will deteriorate rapidly. Check
the battery fluid level often.
Maintain the fluid level
between the upper and lower
level marks.
Add only distilled water. Tap
water contains minerals that are
harmful to a battery.
78
Lower
Mark
Upper
Mark
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 76.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3. Reinstall the battery. See page 77. Make sure the positive terminal is
toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. 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.
79
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
Voltage
Action
(Using constant current
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None required
75%-100%
12.5-12.8 volts
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
None, check at 3
mos. from date of
manufacture
May need slight
charge, if no
charge given,
check in 3 months
Needs charge
Needs charge
0%-25%
11.5 volts or less
80
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
81
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the following items:
• Wheel bearings
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components
• Switches and controls
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
82
MAINTENANCE
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.
Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean chrome
wheels more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as outlined above.
83
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 81.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean fuel treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems,
stabilizes fuel and removes carbon deposits from pistons, rings,
valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.
4. Stop the engine.
5. Turn the fuel valve off.
6. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 58.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Drain the sediment tube.
84
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Change fluids as recommended in the Periodic
Maintenance Chart beginning on page 52.
• Rear gearcase
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
Fog the Engine
Use POLARIS Engine Fogging Oil. Follow label directions carefully.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 52.
Battery Storage
See pages 78-79 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
85
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the fuel valve off.
5. Secure the fuel cap, oil cap and
seat.
6. Remove the key to prevent loss
during transporting.
7. Always tie the frame of the ATV to
the transporting unit securely with
suitable straps or rope. Do not
attach tie straps to the front bumper, racks or handlebars.
86
ADJUSTMENTS
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring
is adjusted by rotating the
adjuster either clockwise or
counterclockwise to increase or
decrease spring tension.
Accessory springs are available
through your POLARIS dealer.
Adjuster
87
ADJUSTMENTS
Handlebars
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 serious injury or death. Follow the
adjustment procedures exactly, or see your POLARIS dealer for service.
The handlebars can be adjusted for rider preference.
1. Remove the handlebar
cover.
Cover
2. Loosen (do not remove) the
four handlebar clamp bolts.
3. Adjust the handlebar to the
desired height.
4. Be sure the handlebars do
Handlebar
not contact the gas tank or
Bolts
any other part of the
machine when turned fully
to the left or right.
5. Tighten the front handlebar
clamp bolts first, then
tighten the rear bolts.
Torque to 25 ft. lbs. (34
Nm).
6. Reinstall the handlebar
cover. Tighten screws to 3.5
ft. lbs. (4.7 Nm).
88
3.5 ft. lbs.
(4.7 Nm)
25 ft. lbs.
(34 Nm)
ADJUSTMENTS
Carburetor
Your POLARIS ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 8,000 feet (2400 m) and temperatures above 15° F (-9° C). Refer to the specifications section beginning
on page 96 for carburetor and jetting specifications.
Any jetting changes must be made only by an authorized POLARIS
dealer. Always see your dealer if jetting changes are needed.
Tip: 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.
Carburetor/Engine Idle RPM Adjustment
If the engine idle speed is not satisfactory, and all other conditions are
favorable, the carburetor can be adjusted.
1. Place the transmission in gear.
2. Lock the parking brake.
3. Start the engine and allow it to warm up for approximately five minutes.
4. Turn the carburetor idle screw in (clockwise) to raise RPM. Turn the
screw out (counterclockwise) to lower RPM.
89
ADJUSTMENTS
Speed Control System
This vehicle is delivered in a limited mode to have a maximum speed at
or below 20 MPH (32 km/h). The vehicle contains a means for limiting
the maximum speed to 20 MPH (32 km/h) and 30 MPH (48 km/h) or
less. The maximum unrestricted speed capability is 38 MPH (61 km/h)
or less.
The dealer CANNOT, under any circumstances, either prior to the sale
or later, even at the consumer's request, remove or adjust any speed limiting devices.
Your POLARIS ATV has an adjustable throttle limiting screw. Speed
limiting devices may be adjusted/removed only by consumers when they
determine that their child is capable of handling the additional speed.
90
ADJUSTMENTS
Speed Control System
Throttle Stop Speed Control System
The speed control system has
two options for limiting speed.
Adjusting the speed limit screw
allows you to control vehicle
speed between 0 and 30 MPH
(48 km/h). This adjustment controls how far the throttle opens.
To remove the speed limiting
entirely and allow operation up
to the maximum vehicle speed
of 38 MPH (61 km/h), the speed
limit bracket can be removed.
1. To adjust the speed limit
screw, loosen the jam nut.
2. Turn the screw inward to
reduce the speed. Turn the
screw outward to increase
speed up to the 30 MPH (48
km/h) maximum. The throttle lever will stop against
the speed control bracket at
the maximum setting.
3. Tighten the jam nut after
adjusting.
4. To allow the vehicle to
operate to the maximum of
38 MPH (61 km/h), remove
the bracket fastener on the
throttle assembly and
remove the bracket.
Bottom Views of
Throttle Assembly
Adjusted Below
Maximum
Limiting Screw
Jam Nut
Adjusted at
Maximum
Bracket Fastener
Bracket
Removed
91
ADJUSTMENTS
Throttle Cable Freeplay
Adjust throttle cable freeplay at the handlebar.
1. Slide the boots off the inline cable adjuster sleeve. Loosen the
adjuster locknut.
2. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is
achieved at the thumb lever. While adjusting freeplay, be sure to flip
the throttle lever back and forth several times.
3. Tighten the lock nut and slide the boots over the cable adjuster until
they touch at the midpoint of the adjuster.
Boot
Boot
Sleeve
Lock Nut
92
TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Tripped circuit breaker
Low battery voltage
Loose battery connections
Loose solenoid connections
Solution
Reset the breaker
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Clogged fuel valve or filter
Water is present in fuel
Fuel valve is turned off
Old or non-recommended fuel
Fouled or defective spark plug(s)
No spark to spark plug
Overuse of choke
Water or fuel in crankcase
Low battery voltage
Mechanical failure
Solution
Turn fuel valve to reserve, refuel
Inspect and clean or replace
Drain the fuel system and refuel
Turn the fuel valve on
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs, verify stop switch is on
Inspect, clean and/or replace spark plugs
Immediately see your POLARIS dealer
Recharge the battery to 12.8 VDC
See your dealer
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Solution
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
93
TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Idle set too low
Solution
Replace with recommended fuel
See your dealer
Set gap to specs or replace plugs
Adjust idle speed
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Low battery voltage
Kinked or plugged fuel tank vent line
Incorrect fuel
Clogged air filter
Reverse speed limiter malfunction
Electronic throttle control malfunction
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Low octane fuel
Clogged fuel filter
Incorrect jetting
Possible Rich Fuel Cause
Overuse of choke
Fuel is very high octane
Incorrect jetting
94
Solution
Inspect, clean and/or replace spark
plug(s)
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Solution
Add or change fuel, clean the fuel system
Replace with recommended fuel
Replace filter
See your dealer
Solution
Inspect, clean and/or replace spark plugs
Replace with lower octane fuel
See your dealer
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Water is present in fuel
Overuse of choke
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Incorrect fuel
Clogged air filter
Reverse speed limiter malfunction
Electronic throttle control malfunction
Other mechanical failure
Overheated engine
Solution
Refuel, cycle key to ON position three
times for 5 seconds each, then start
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark plugs
Inspect, clean and/or replace spark
plug(s)
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Clean engine exterior; see your
POLARIS dealer
95
SPECIFICATIONS
Phoenix 200
Maximum Weight Capacity
Dry Weight
Fuel Capacity
Engine Oil Capacity
Transmission Oil
Rear Gearcase Oil
Rear Rack Capacity
Hitch Tongue Weight Capacity
Hitch Towing Weight Capacity
Overall Length
Overall Width
Overall Height
Wheelbase
Ground Clearance
Minimum Turning Radius
Engine Type
Lubrication
Engine Cooling
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Carburetor
Pilot Jet
Main Jet
Air Screw
Jet Needle
Ignition System
Ignition Timing
Spark Plug / Gap
Driving System Type
Shift Type
Drive Ratio, Front
Tires, Front
Tires, Rear
Front Suspension
Rear Suspension
96
215 lbs. (98 kg) (includes weight of operator,
cargo and accessories)
395 lbs. (179 kg)
2.5 gal. (9.5 l)
41 oz. (1200 ml)
18.6 oz. (550 ml)
4 oz. (120 ml)
70 lbs. (31.7 kg)
30 lbs. (13.6 kg) (Rear rack weight and tongue
weight not to exceed 30 lbs./13.6 kg)
300 lbs. (136 kg)
65 in. (165 cm)
42 in. (106.7 cm)
42 in. (106.7 cm)
45 in. (114.3 cm)
5.7 in. (14.5 cm)
65 in. (165.1 cm) unloaded
4-Cycle, Single Cylinder
Wet sump
Air
196 cc
65 x 59
210w @5000 rpm
9.2:1 Full Stroke
1 / 22 mm (VM Type)
40
98
1 Turn Out
2MKNN-4 clip
DC CDI
32q +/- 2q @ 3000 RPM
NGK CR6HSA / 0.6-0.7 mm
Constant Variable Transmission (CVT)
Side Lever (F/N/R)
N/A
21x7-10 / 4 psi (27.6 kPa)
20x10-9 / 4 psi (27.6 kPa)
Dual A-Arm w/7 in. (17.8 cm) travel
Mono-Shock Swing Arm w/6.5 in. (16.5 cm)
travel
SPECIFICATIONS
Phoenix 200
Shock Adjustment
Brakes, Front
Brakes, Rear
Brake, Foot
Brake, Parking
Headlight
Taillight
Brake Light
Battery
Electric Start
DC Plug-In (rear)
Windshield
Neutral Indicator
Reverse Indicator
Tool Kit
CAM
Hydraulic Disc
Mechanical Drum
Mechanical Drum, Rear Brake
Mechanical, Rear
Front Cover, Hi/Lo 35W Halogen
12V 5W
12V 21W
12V 12 AH
Standard
Accessory
Accessory
Standard
Standard
Standard
Jetting Chart
Carburetor Jetting
*Shaded cells indicate factory settings.
ALTITUDE
Meters
(Feet)
°F:
°C:
Main Jet
0-600
Pilot Jet
(0-2000)
Clip Position
Main Jet
600-1200 Pilot Jet
(2000-4000)
Clip Position
Main Jet
1200-1800 Pilot Jet
(4000-6000)
Clip Position
Main Jet
1800-2400 Pilot Jet
(6000-8000)
Clip Position
2400-3000 Main Jet
(8000Pilot Jet
10000)
Clip Position
3000-3700 Main Jet
(10000Pilot Jet
12000)
Clip Position
AMBIENT TEMPERATURE
Below -25
-30 to -10
-15 to +5
0 to +20
Below-35
-34 to -23
-26 to -15
-18 to -7
+15 to +35 +30 to +50 +45 to +65 Above +60
-9 to +2
-1 to +10
+7 to +18
Above +16
98
40
#5
98
40
#5
98
40
#5
98
40
#5
96
40
#5
96
40
#5
98
40
#5
98
40
#5
98
40
#5
98
40
#5
96
40
#5
96
40
#5
98
40
#5
98
40
#5
98
40
#5
98
40
#5
96
40
#5
96
40
#5
98
40
#5
98
40
#5
98
40
#5
98
40
#5
96
40
#5
96
40
#5
98
40
#4
98
40
#4
98
40
#4
98
40
#4
96
40
#4
96
40
#4
98
40
#4
98
40
#4
98
40
#4
98
40
#4
96
40
#4
96
40
#4
98
40
#4
98
40
#4
98
40
#4
98
40
#4
96
40
#4
96
40
#4
98
40
#4
98
40
#4
98
40
#4
98
40
#4
96
40
#4
96
40
#4
The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR
1051.115(d)(3).
Clutching Chart
Altitude in Meters (Feet)
0-1800 (0-6000)
1800-3700 (6000-12000)
Roller Weight Grams Each
6 @ 14.7 grams
6 @ 9.5 grams
97
POLARIS PRODUCTS
Part
Description
Number
2870791
2878920
2878919
2878068
2878069
2870465
2871312
2871322
2871423
2876160
2872276
2871460
2871515
2871551
2871329
2871326
2870652
2872189
2871956
2859044
98
Engine Lubricant
Fogging Oil (12 oz. Aerosol)
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./
.95 l)
AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./
3.8 l)
Pump for Gallon Jug
Grease / Specialized Lubricants
Grease Gun Kit, All Season Grease
All Season Grease (3 oz./89 ml cartridge)
All Season Grease (14 oz./414 ml cartridge)
ATV Angle Drive Fluid (qt./.95 l)
ATV Angle Drive Fluid (2.5 gal./9.5 l)
Premium Starter Grease
U-Joint Grease (3 oz./89 ml cartridge)
U-Joint Grease (14 oz./414 ml cartridge)
Dielectric Grease (Nyogel™)
Additives / Miscellaneous
Carbon Clean
Fuel Stabilizer
DOT 4 Brake Fluid
Loctite™ 565 Thread Sealant
POLARIS Battery Tender™ Charger
WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX
MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against
defects in material or workmanship. POLARIS further warrants that the spark arrestor in
this product will meet the efficiency requirements of USFS standard 5100-1C for at least
1000 hours when subjected to normal use and when maintenance and installation are in
accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts
and begins on the date of purchase by the original retail purchaser. This warranty is
transferable to another owner during the warranty period through a POLARIS dealer,
but any such transfer will not extend the original term of the warranty. The duration of
this warranty may vary by international region based upon local laws and regulations.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days of purchase. Upon receipt of this
registration, POLARIS will record the registration for warranty. No verification of
registration will be sent to the purchaser as the copy of the Warranty Registration Form
will be your proof of warranty coverage. 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 VEHICLE IS
REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle 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
This POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF
DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental
damage, normal wear and tear, abuse or improper handling. This warranty also does not
cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained, or used for purposes other than for which it was
designed.
This warranty excludes damages or failures resulting from: improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external stress,
heat, cold or contamination; operator error or abuse; improper component alignment,
tension, adjustment or altitude compensation; snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket or unapproved components, accessories, or attachments; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
99
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty excludes damages or failures caused by abuse, accident, fire, or any other
cause other than a defect in materials or workmanship and provides no coverage for
consumable components, general wear items, or any parts exposed to friction surfaces,
stresses, environmental conditions and/or contamination for which they were not
designed or not intended, including but not limited to the following items:
•
•
•
•
•
•
•
•
•
•
•
Wheels and tires
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Light bulbs/Sealed beam lamps
Filter
Lubricants
Bushings
•
•
•
•
•
•
•
•
•
•
•
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components and fluids
Circuit breakers/Fuses
Electronic components
Spark plugs
Sealants
Coolants
Bearings
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is
not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage,
transportation costs, hotels, meals, shipping or handling fees, product pick-up or
delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or
personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, 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. THIS EXCLUSION OF CONSEQUENTAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL
SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS
ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. P0LARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO
NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
100
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing
Dealer. When requesting warranty service you must present your copy of the Warranty
Registration From 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.
In the country where your product 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 product was purchased,
Warranty and Service Bulletin repairs may be requested from any authorized POLARIS
dealer that sells the same line as your product.
Outside the country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased,
you should take your product 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. Product
importation rules vary considerably from country to country. You may be required to
present documentation of your move to POLARIS in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS in order to
register your product in your new country. You should warranty register your product at
a local POLARIS dealer in your new country immediately after you move to continue
your warranty coverage and to ensure that you receive information and notices regarding
your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of
the country in which the product was originally purchased, all warranty coverage will be
denied. You must nonetheless register your product under your name and address with a
local POLARIS dealer in your country to ensure that you receive safety information and
notices regarding your product.
101
WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS
SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED
LOCATION. This policy does not apply to products that have received authorization for
export from POLARIS. Dealers may not give authorization for export. You should
consult an authorized dealer to determine this product’s warranty or service coverage if
you have any questions. This policy does not apply to products 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 Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and you have
not followed the procedure set above, your product will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. Products
registered to Government officials or military personnel on assignment outside of the
country where the product was purchased will continue to be covered by the Limited
Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state or in different countries. If any of the above terms are void
because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
102
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first
purchased, this emissions-certified vehicle is designed, built and equipped so it
conforms with applicable U.S. Environmental Protection Agency emission regulations.
POLARIS warrants that the vehicle is free from defects in materials and workmanship
that would cause it to fail to meet these regulations.
The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles
starts on the date of purchase by original retail purchaser and continues for a period of
500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30
calendar months from the date of purchase, whichever comes first. The warranty period
for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by
original retail purchaser and continues for a period of 250 hours of engine operation,
2500 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of
purchase, whichever comes first. This EPA emissions warranty period is extended for at
least as long as the standard factory warranty that Polaris provides on the vehicle as a
whole. The EPA emissions warranty period does not further extend if you purchase
additional warranty coverage in the form of a service contract or other paid warranty
extension, but emission-related parts may be covered subject to the terms of any such
paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle’s regulated emissions, and it covers components of systems whose only purpose
is to control emissions. Repairing or replacing other components not covered by this
warranty is the responsibility of the vehicle owner. This emissions limited warranty does
not cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust
emissions:
• Aftertreatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
103
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative
emissions:
•
•
•
•
•
•
•
•
•
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of POLARIS, repair or replacement of any defective materials, components or
products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents, abuse or
improper handling, maintenance or use. This limited warranty also does not cover any
engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or
defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
104
WARRANTY
U.S.A. EPA Emissions Limited Warranty
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been caused
by the owner’s or operator’s improper maintenance or use, by accidents for which
POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission
control devices or systems on your vehicle. POLARIS recommends that you contact an
authorized POLARIS dealer to perform any service that may be necessary for your
vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law.
California Residents
Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only
the 50-state models are certified for sale in California. The 50-state models available for
sale in California are identified by the letter “C” in the model name (e.g.,
R13UH88A_C). The POLARIS 50-state models are designed and built with features
such as a reduced cargo box capacity. Any modifications to these features may be a
violation of the applicable California regulations and may void this limited emissions
warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please
contact POLARIS Customer Assistance.
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
105
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and services performed.
DATE
106
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
107
INDEX
A
D
Air Filter . . . . . . . . . . . . . . . . . . . . . 68
Drivetrain Break-In . . . . . . . . . . . . . . 32
Driving Downhill. . . . . . . . . . . . . . . . 43
Driving in Reverse. . . . . . . . . . . . . . . 47
Driving on a Sidehill . . . . . . . . . . . . . 42
Driving on Slippery Surfaces . . . . . . 40
Driving Over Obstacles . . . . . . . . . . . 46
Driving Procedures . . . . . . . . . . . . . . 38
Driving Through Water . . . . . . . . . . . 45
Driving Uphill . . . . . . . . . . . . . . . . . . 41
B
Battery . . . . . . . . . . . . . . . . . . . . 75-80
Charging (Conventional) . . . . . 79
Charging (Sealed Battery) . . 79-80
Fluid (Conventional) . . . . . . . . 78
Installation . . . . . . . . . . . . . . . . 77
Removal. . . . . . . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . . . 78
Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Adjustments (Rear) . . . . . . . . 63
Brake Fluid . . . . . . . . . . . . . . . . . . . 29
Brake Inspections (Front) . . . . . . . . 62
Brake Maintenance . . . . . . . . . . . 62-63
Brake, Parking . . . . . . . . . . . . . . . . . 28
Brakelight . . . . . . . . . . . . . . . . . . . . 69
Brakes . . . . . . . . . . . . . . . . . . . . . 26-29
Front Brakes (Right Lever) . . . 26
Rear Brakes (Foot Brake) . . . . 27
Rear Brakes (Left Lever) . . . . . 27
Break-In Period . . . . . . . . . . . . . . . . 32
C
Camber Adjustment . . . . . . . . . . . . . 87
Carburetor . . . . . . . . . . . . . . . . . . . . 89
Carburetor Adjustment . . . . . . . . . . 89
Cargo . . . . . . . . . . . . . . . . . . . . . . 48-49
Caster Adjustment . . . . . . . . . . . . . . 87
Choke. . . . . . . . . . . . . . . . . . . . . . . . 30
Chrome Wheel Care . . . . . . . . . . . . 83
Cleaning and Storage. . . . . . . . . . 81-85
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching Chart . . . . . . . . . . . . . . . . 97
Cold Weather Operation . . . . . . . . . 37
Constant Variable Transmission . . . 74
Consumer Product Safety . . . . . . . . . 7
Corrosion Removal, Chrome . . . . . . 83
Crankcase Emission Control System 51
CVT Drying . . . . . . . . . . . . . . . . . . . 74
CVT System. . . . . . . . . . . . . . . . . . . 74
E
Electromagnetic Interference. . . . . . . 51
Emissions Limited Warranty . . 104-105
Engine Break-In. . . . . . . . . . . . . . . . . 32
Engine Fogging . . . . . . . . . . . . . . . . . 85
Engine Idle RPM Adjustment . . . . . . 89
Engine Oil . . . . . . . . . . . . . . . . . . . . . 57
Equipment Modifications . . . . . . . . . . 9
Etiquette, Trail Riding . . . . . . . . . . . . 34
Exhaust Emission Control System . . 51
Eye Protection . . . . . . . . . . . . . . . . . . . 9
F
Fluid, Brake . . . . . . . . . . . . . . . . . . . . 29
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 30
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap . . . . . . . . . . . . . . . . . . 30
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 30
G
Gasoline Handling . . . . . . . . . . . . . . . 11
Gear Selector . . . . . . . . . . . . . . . . . . . 31
Gearcase Oil . . . . . . . . . . . . . . . . . . . 61
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Handlebar Adjustment. . . . . . . . . . . . 88
Hauling Cargo . . . . . . . . . . . . . . . 48-49
Headlamp Replacement. . . . . . . . . . . 69
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8
I
Idle RPM Adjustment . . . . . . . . . . . . 89
Immersion . . . . . . . . . . . . . . . . . . . . . 72
Indicator Lights . . . . . . . . . . . . . . . . . 31
108
INDEX
J-K-L-M-N
S
Jetting Chart . . . . . . . . . . . . . . . . . . . 97
Key Switch . . . . . . . . . . . . . . . . . . . . 24
Kick-Start Lever . . . . . . . . . . . . . . . . 31
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 44
Lights . . . . . . . . . . . . . . . . . . . . . . . . 69
Headlamp Replacement . . . . . . 69
Taillight/Brakelight. . . . . . . . . . 69
Lubrication Guide . . . . . . . . . . . . . . . 56
Maintenance Chart . . . . . . . . . . . 52-55
Modifications . . . . . . . . . . . . . . . . . . . 9
Noise Emission Control System . . . . 51
Spark Plugs . . . . . . . . . . . . . . . . . 70-71
Speed Control System. . . . . . . . . 90-91
Spring Adjustments, Rear . . . . . . . . . 87
Starting the Engine . . . . . . . . . . . 36-37
Starting, Kick-Start Lever. . . . . . . . . 31
Steering Assembly . . . . . . . . . . . . . . 65
Storage . . . . . . . . . . . . . . . . . . . . 81-85
Switches . . . . . . . . . . . . . . . . . . . 24-25
Engine Stop Switch. . . . . . . . . . 24
Main Key Switch . . . . . . . . . . . 24
Override Switch . . . . . . . . . . . . 25
O
Oil
Engine . . . . . . . . . . . . . . . . . . . . 57
Rear Gearcase . . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . 60
Oil and Filter Change . . . . . . . . . 58-59
Oil Level, Engine . . . . . . . . . . . . . . . 57
Oil Recommendations. . . . . . . . . . . . 57
Operation on Public Lands . . . . . . . . 51
Override Switch . . . . . . . . . . . . . . . . 25
P
Panel Removal . . . . . . . . . . . . . . . . . 65
Parking Brake . . . . . . . . . . . . . . . . . . 28
Parking on an Incline . . . . . . . . . . . . 50
Periodic Maintenance Chart . . . . 52-55
POLARIS Product List . . . . . . . . . . . 98
Polishing the Vehicle . . . . . . . . . . . . 82
Pre-Ride Checklist . . . . . . . . . . . . . . 35
R
Reverse Operation. . . . . . . . . . . . . . . 47
Riding Area. . . . . . . . . . . . . . . . . . . . 34
Riding Gear. . . . . . . . . . . . . . . . . . . 8-9
T
Taillight. . . . . . . . . . . . . . . . . . . . . . . 69
Throttle Cable Freeplay . . . . . . . . . . 92
Throttle Lever . . . . . . . . . . . . . . . . . . 25
Throttle Stop Speed Control System 91
Tire Tread Depth. . . . . . . . . . . . . . . . 66
Tires . . . . . . . . . . . . . . . . . . . . . . 66-67
Front Wheel Hub Tightening . . 66
Tread Depth . . . . . . . . . . . . . . . 66
Wheel Installation . . . . . . . . . . . 67
Wheel Nut Torque . . . . . . . . . . 67
Wheel Removal . . . . . . . . . . . . 67
Toe Alignment . . . . . . . . . . . . . . . . . 64
Trail Etiquette . . . . . . . . . . . . . . . . . . 34
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil. . . . . . . . . . . . . . . . 60
Transmission Oil Recommendations 60
Transmission System (CVT) . . . . . . 74
Transporting the Vehicle . . . . . . . . . 86
Tread Lightly . . . . . . . . . . . . . . . . . . 34
Turning Around on a Hill . . . . . . . . . 44
Turning the Vehicle . . . . . . . . . . . . . 39
V
S
Vehicle Identification Numbers . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . 72
Safe Operation Practices . . . . . . . . . . 33
Safety Labels. . . . . . . . . . . . . . . . 20-23
Safety Training . . . . . . . . . . . . . . . . . . 7
Safety Warnings . . . . . . . . . . . . . 10-19
Severe Use . . . . . . . . . . . . . . . . . . . . 52
Side Panel Removal . . . . . . . . . . . . . 65
Sidehilling . . . . . . . . . . . . . . . . . . . . . 42
Signal Words. . . . . . . . . . . . . . . . . . . . 4
Spark Arrester . . . . . . . . . . . . . . . . . . 73
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . . . 81-82
Wheel Hub Tightening . . . . . . . . . . . 66
Wheel Installation . . . . . . . . . . . . . . . 67
Wheel Nut Torque Specifications. . . 67
Wheel Removal . . . . . . . . . . . . . . . . 67
W
109
PMS 419
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
S on public roads - a collision can occur with another
vehicle.
S with a passenger - passengers affect balance and
steering and increase risk of losing control.
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect
handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polaris.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9924651 Rev 01
Printed in USA
*9924651
*