2016 RZR170 EFI AGE 10 with EPA updates (2).fm

2016 RZR170 EFI AGE 10 with EPA updates (2).fm
PMS 419
2016
Owner's Manual
for Maintenance
and Safety
WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
Visit us at www.polaris.com
1
POLARIS® and RZR® are trademarks of POLARIS Industries Inc.
Copyright 2015 POLARIS Industries 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
2016 RZR 170 Owner’s Manual
P/N 9926400
2
WELCOME
Dear Parents:
We believe your children should have the opportunity to enjoy the
POLARIS riding experience along with you. We encourage you to teach
your children to ride safely, and to help ensure the future of recreational
sports, please teach them to show respect for our environment and for
the rights of others while operating the vehicle.
This vehicle is not a toy and can be hazardous to operate. We've
provided this owner’s manual and an instructional video to help you and
your children learn about the safe operation and care of your new
POLARIS vehicle. Before your children drive or ride in the vehicle,
please read and make sure they read this owner’s manual. Watch the
instructional video with them. Make sure all operators and passengers
understand and follow all of the instructions and warnings contained in
this owner’s manual and video. Make sure they understand that the
vehicle must be used under adult supervision at all times.
After reading this owner’s manual and watching the video, help your
child practice the New Operator Driving Procedures on pages 42-43.
Never allow a child under age 10 to operate or ride as a passenger in
this vehicle. Children differ in skills, physical abilities and judgement.
Please supervise the use of the vehicle at all times. Permit continued use
only if you determine that your child has the ability and maturity to
operate safely.
For your child’s safety, be sure your child can reach and operate all
RZR 170 controls, including steering wheel, accelerator and brake
pedals, and ignition switch. Make sure your child is not too tall to ride
safely in this vehicle. See page 12.
The vehicle’s speed control system allows adults to limit vehicle speed
for new and inexperienced operators. Please see page 35 for more
information.
The preventive maintenance program outlined in this manual is
designed to ensure that all critical components on your child's vehicle
are thoroughly inspected at specific intervals. Always follow all of the
instructions and recommendations in this manual to ensure the vehicle
remains in safe operating condition at all times.
This POLARIS vehicle is not designed for adult use. Serious damage
may occur if the maximum weight capacity is exceeded. Refer to
vehicle labels and to the specifications section beginning on page 92 for
the maximum weight capacity.
3
WELCOME
Dear Young Operators:
Before you ride your new POLARIS vehicle, 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 be safe while you enjoy riding
your new vehicle, and that's why it’s very important that you read this
owner’s manual and watch the instructional video. Make sure you
understand and follow all of the instructions and warnings in this
owner’s manual and video. Ask your parents to explain anything you
don't understand.
Your safety and the safety of others is the most important thing to think
about at all times. Pay attention when you see this symbol:
This is the safety alert symbol. When you see this symbol on your vehicle
or in this manual it means PAY ATTENTION because you could die or be
seriously injured if you don't follow the instructions.
After reading this owner’s manual and watching the video, complete the
New Operator Driving Procedures on pages 42-43. Show your parent
that you understand how to drive safely.
Enjoy riding your new POLARIS vehicle!
4
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Features and Controls . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Emission Control Systems . . . . . . . . . . . . . . . 52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . 94
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 95
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 106
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5
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.
6
INTRODUCTION
WARNING
Failure to follow the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. 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.
• Never operate this vehicle without proper instruction. All operators and
supervising adults must watch the instructional video that was provided with
the vehicle. Read this owner’s manual and review the safety DVD that came
with your vehicle. A free extra copy of the DVD can be obtained by contacting
your local POLARIS dealer. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.
• For your child’s safety, be sure your child can reach and operate all RZR 170
controls, including steering wheel, accelerator and brake pedals, and ignition
switch. No person under the age of 10 may ride as a passenger in this vehicle.
All riders must be able to sit with backs against the seat, both feet flat on the
floor and both hands on the steering wheel (if driving) or on a passenger hand
hold.
• Always follow the age guidelines for your vehicle. Operation is prohibited for
anyone under age 10. Never operate with a passenger under age 10.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Complete the New Operator Driving Procedures outlined on pages 42-43.
Never allow a guest to operate this vehicle until the guest has watched the
instructional video and has completed the New Operator Driving Procedures.
7
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.
Vehicle Identification Number
(left front wheel well)
Engine Serial Number
(left rear wheel well)
Key
Number
####
Vehicle Model Number: ___________________________________________________
Vehicle Identification Number: ______________________________________________
Engine Serial Number: ___________________________________________________
Key Number ____________________________________________________________
8
SAFETY
Equipment Modifications
Your POLARIS vehicle is designed to provide safe operation when used as
directed.
WARNING! Modifying this vehicle in any way can change the top speed,
stability and handling performance of this vehicle. Modifications that increase
speed, decrease stability or change performance may present a greater risk to
inexperienced or younger operators and could result in loss of control and
serious injury or death. Use only POLARIS-approved accessories to modify this
vehicle. Review all vehicle changes with your child prior to operating.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if
any non-POLARIS-approved equipment and/or modifications have been added
to the vehicle that increase speed or power.
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
9
SAFETY
Safe Riding Gear
The driver and passenger must wear helmet, eye protection, gloves,
long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all
times. Protective gear reduces the chance of injury.
Eye
Protection
Long
Sleeves
Helmet
Gloves
Over-the-Ankle
Boots
Long
Pants
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
051039
distinguishing number of the country which has
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
10
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this 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
Wear gloves for comfort and for protection from sun, cold weather and
other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride
a POLARIS vehicle with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the driver and passenger cab
area. The condition occurs most frequently when a vehicle is being
operated in high ambient temperatures at low speeds and/or high load
conditions for an extended period of time. The use of certain
windshield, roof and/or cab systems may contribute to this condition by
restricting airflow. Any discomfort due to heat buildup in this area can
be minimized by wearing proper riding apparel and by varying speeds to
increase airflow.
11
SAFETY
Safety Warnings
WARNING
Failure to operate this vehicle 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 and in the safety DVD
provided with your vehicle.
Be sure to read all of the following warnings about driving hazards and how to
avoid them. These warnings are provided for your child's safety. Be sure to
explain to your young driver that the hazards outlined in this section of this
owner’s manual MUST be avoided at all times. See the OPERATION section of
this owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
and the supervising adult must understand how
to operate the vehicle properly in different
situations and on different types of terrain.
Complete the New Operator Driving
Procedures outlined on pages 42-43.
All operators must read and understand this
owner’s manual and all warning and instruction
labels before operating the vehicle. Never allow
a guest to operate this vehicle until the guest
has read this manual and all product labels and
has completed the New Operator Driving
Procedures outlined on pages 42-43.
Age Restrictions
This vehicle is for recreational use by young
operators under adult supervision ONLY.
Operation is prohibited for anyone under age 10.
Never operate with a passenger under age 10.
All riders must be able to sit with backs against
the seat, both feet flat on the floor and both
hands on the steering wheel (if driving) or on a
passenger hand hold.
Rider Height
Some riders may be too tall to ride safely in
this vehicle. Do not operate or ride in this
vehicle if the clearance between the top of your
helmet and the overhead cab frame is less
than 2 inches (5 cm).
12
Minimum
2 inches
(5 cm)
SAFETY
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the
vehicle is in safe operating condition
before operating increases the risk of an
accident.
Always inspect the vehicle before each
use to make sure it's in safe operating
condition. See page 38.
Always follow the inspection and
maintenance procedures and schedules
described in this owner’s manual. See
page 53.
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of serious injury in the
event of an accident.
Operator and passenger must always
wear an approved helmet that fits properly
and eye protection (goggles or face
shield).
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances. Riders must wear
seat belts at all times. Always make sure the seat belts are secured for both the
operator and passenger before riding.
Cab Nets
Riding in this vehicle without using the cab nets (or doors, if equipped) increases
the risk of serious injury or death in the event of an accident or rollover. Always
use the cab nets (or doors) while riding in this vehicle. Always keep hands and
feet inside the vehicle at all times.
13
SAFETY
Safety Warnings
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating or riding in this vehicle.
Carrying a Passenger
Never carry a passenger until you have operated
this vehicle for at least four hours and have
completed the New Operator Driving Procedures
outlined on pages 42-43.
Carrying Multiple Passengers
A passenger must always be seated in a
passenger seat with seat belt secured.
Carrying more than one passenger in this
vehicle can affect the operator’s ability to
steer and operate the controls, which
increases the risk of loss of control and
accident or rollover. Never carry more than
one passenger in this vehicle.
Operating on Pavement
This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and may
increase the risk of loss of control and accident or rollover. Avoid operating the
vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and
avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a
collision with another vehicle. Never
operate this vehicle on any public street,
road or highway, including dirt and gravel
roads (unless designated for off-highway
use).
14
SAFETY
Safety Warnings
Operating at Excessive Speeds
Operating this vehicle 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, your skills and
experience and your
passengers’ skills and
experience.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
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.
Physical Control of the Vehicle
Removing hands from the steering wheel or hand holds or removing feet from
the floor while riding increases the risk of loss of control and accident or rollover.
The operator should always keep both hands on the steering wheel during
operation. A passenger should always be seated in the passenger seat with
both feet on the floor and with both hands securely grasping the hand holds.
Always keep hands and feet inside the vehicle at all times.
Jumps and Stunts
Exhibition driving increases the risk of
an accident or rollover. DO NOT do
power slides, “donuts”, jumps or other
driving stunts. Avoid exhibition driving.
15
SAFETY
Safety Warnings
Driving Downhill Improperly
Driving down a hill improperly could cause
loss of control or rollover. Always follow
proper procedures for driving down a hill
as described in this owner’s manual. See
page 47.
+15°
Improper Hill Climbing
Improper hill climbing could cause loss of
control or rollover. Use extreme caution
when operating on hills. Always follow proper
procedures for hill climbing as described in
this owner’s manual. See page 46. Never
operate the vehicle on hills steeper than 15
degrees.
+15°
16
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill
could cause a rollover. Maintain a steady speed
when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is
fully stopped. Place the transmission in reverse
and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to
control speed.
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 this owner’s manual. See page 47.
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.
17
SAFETY
Safety Warnings
Operating on Sand or Slippery
Terrain
Operating on sand or on excessively rough,
slippery or loose terrain could cause loss of
traction, loss of control, accident or rollover.
Always use extra caution when operating on
sand or on rough, slippery or loose terrain.
Do not operate on excessively rough,
slippery or loose terrain.
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 50.
Before shifting into reverse gear, always
check for obstacles or people behind the
vehicle. When it's safe to proceed, back
slowly.
Improper Tires and Maintenance
Operating this vehicle with improper tires or
with improper or uneven tire pressure could
cause loss of control, accident or rollover.
Always use the size and type of tires specified
for your vehicle. Always maintain proper tire
pressure as described in this owner's manual
and on safety labels.
18
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. Never attempt
to operate over large obstacles such
as large rocks or fallen trees. Always
follow the proper procedures
outlined in this manual when
operating over obstacles. See page
49.
Operating Through Water
Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, rollover or accident. Never
operate in fast-flowing water or in water
that exceeds the floor level.
Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 48.
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.
19
SAFETY
Safety Warnings
Overloading the Vehicle
Overloading the vehicle or carrying/towing loads may cause changes in stability
and handling, which could cause loss of control or an accident.
• Never tow objects or carry loads with this vehicle.
• Never exceed the maximum weight capacity for this vehicle. See page 23.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belts, rollover protection
devices, brakes, throttle and steering systems.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water can
result in the vehicle and/or riders falling
through the ice. Never operate this vehicle on
a frozen body of water.
20
SAFETY
Safety Warnings
Refueling
Gasoline is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling gasoline.
• Never allow a child to refuel or handle gasoline.
• Always stop the engine when refueling.
• Always refuel outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the refueling area or
where gasoline is stored.
• Never refuel while a person is in the vehicle.
• Do not over fill 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.
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.
Operate this vehicle only outdoors or in well-ventilated areas.
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. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 10 or without proper training. This could result in an
accident or rollover. Always remove the ignition key when the vehicle is not in
use.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
21
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.
Dash Warning Label
UNDER
10
Rear Warning Label
22
SAFETY
Safety Labels and Locations
Rear Warning Label
WARNING
Improper vehicle use can result in SEVERE INJURY or
DEATH
NEVER allow vehicle to be operated:
• without adult supervision.
• by anyone under age 10.
• with a passenger under age 10.
• with a passenger whose feet cannot touch the floor.
• without all occupants first viewing and understanding safety
video and warning labels.
• with more than one passenger.
• on hills steeper than 15 degrees
15°.
• on paved surfaces - pavement may seriously affect handling
and control.
• with non-POLARIS approved accessories - they may
seriously affect stability.
• at speeds that are too fast for the operator’s skills, the
conditions and/or the terrain.
ALWAYS require operator and passenger to:
• wear seat belts, grab hand holds (passenger) and plant feet firmly on the floor.
• secure cab nets.
• keep hands and feet inside vehicle.
• avoid quick turns of the steering wheel and driving stunts such as jumps,
donuts or power slides.
• reduce speed and use extra caution when carrying a passenger.
• watch for branches or other hazards that could enter vehicle.
WARNING
Operation of this vehicle by children under age 10 increases the risk of severe
injury or death.
Adult supervision required for children under age 16.
NEVER permit children under age 10 to operate or ride in this vehicle.
WARNING
VEHICLE ROLLOVER could cause severe injury or death. The cab frame is not
designed or intended to provide rollover protection.
TIRE PRESSURE IN PSI (KPa):
Front: 3 (20.7)
Rear: 3 (20.7)
MAXIMUM WEIGHT CAPACITY 300 lbs. (136 KG)
INCLUDES WEIGHT OF OPERATOR, PASSENGER AND ACCESSORIES.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.
23
FEATURES AND CONTROLS
Component Locations
Your vehicle is equipped with cab nets on both sides of the vehicle. Cab
nets must be used by both operator and passenger at all times. Promptly
replace worn or damaged cab nets with new cab nets, available from
your authorized POLARIS dealer. The vehicle illustrated below is
shown without cab nets only to allow component identification. Always
use the cab nets.
Seat Belts
Dash
Hip Bar
Shifter
Parking
Brake
Seat
(battery under
driver’s seat)
Fuel Tank
Cap
Cab Net
24
Passenger
Hand Hold
FEATURES AND CONTROLS
Component Locations
Cab
Frame
Steering
Wheel
Running
Lights
Brush Guard
Taillight/Brake Light
Muffler
(Spark Arrester)
25
FEATURES AND CONTROLS
Seats
Driver’s Seat Adjustment
1. Lift the seat latch lever located
under the right front edge of the
driver’s seat.
2. While holding the lever
upward, slide the seat forward
or rearward to the desired
position, then release the lever.
3. Slide the seat forward and
rearward to ensure the latch is
engaged. Before operating the
vehicle, always make sure both
seats are securely installed.
Seat Latch Lever
Seat Removal
1. To remove the driver’s seat, lift
the seat latch lever.
2. While holding the lever upward,
slide the seat completely forward
to remove it from the seat
mounting rails.
3. Before operating the vehicle,
always make sure the driver’s
seat is installed and securely
latched.
Slide Seat Forward
4. To remove the passenger seat,
remove the two bolts located at
the front of the seat mounting rails. Slide the seat forward to remove
it from the vehicle. Always reinstall the passenger seat before
operating the vehicle. After reinstalling the seat and bolts, torque
the nuts to 10 ft. lbs. (13.5 Nm).
26
FEATURES AND CONTROLS
Steering Wheel
The steering wheel can be
adjusted upward or downward for
rider preference.
1. Loosen the steering wheel
adjustment bolt.
2. Move the steering wheel
upward or downward to the
desired position.
3. Tighten the bolt to 10 ft. lbs.
(13.5 Nm).
Adjustment Bolt
Passenger Hand Hold
Always adjust the hand hold to a comfortable position for your
passenger before operating. Make sure the adjustment pin and retainer
are securely installed after making adjustments.
1. Remove the retainer from the end of the adjustment pin. Remove
the pin from the post.
2. Slide the post inward or outward to the desired position.
3. Reinstall the pin through the mounting bracket hole, through both
post adjustment holes, and through the remaining bracket hole.
4. Reinstall the retainer to the pin.
A
P o dju s
s i t tm
ion en
Ho t
les
Pin
Retainer
Adjustment
Pin
Mounting
Bracket Holes
27
FEATURES AND CONTROLS
Seat Belts
This POLARIS vehicle is equipped with three-point lap and diagonal
seat belts for the operator and passenger. Always make sure the seat
belts are secured for both the operator and passenger before riding.
To wear the seat belt properly, follow
Seat Belt
this procedure:
Buckles
Seat Belt
Latches
1. Pull the seat belt latch downward
and across your chest toward the
buckle at the inner edge of the seat.
The belt should fit snugly across
your hips and diagonally across
your chest. Make sure the belt is not
twisted.
Tip: The position of the shoulder strap can
be adjusted to the height of the
operator. Have an adult relocate the
mounting bolt to a different position,
making sure the nut and bolt are
tightened securely.
2. Push the latch plate into the buckle
until it clicks.
3. Release the strap, it will selftighten.
4. Press the red release latch on the
buckle to release the seat belt.
28
Nut and
Bolt
FEATURES AND CONTROLS
Seat Belts
Seat Belt Inspection
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.
2. Push the red release latch in the middle of the buckle to make sure it
releases freely.
3. Pull each seat belt completely out and inspect the full length for any
damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly, have the seat belt
system checked and/or replaced by an authorized POLARIS dealer.
4. To clean dirt or debris from the seat belts, sponge the straps with
mild soap and water. Do not use bleach, dye or household
detergents.
29
FEATURES AND CONTROLS
Cab Nets
Riding in this vehicle without using the cab nets increases the risk of
serious injury or death in the event of an accident or rollover.
Adjusters/Latches
Screw
Cab nets must be used by both operator and passenger at all times. Make
sure all latches are secure before operating the vehicle.
Always inspect cab nets for tightness, wear and damage before each use
of the vehicle. Use the strap adjusters to tighten any loose straps.
Promptly replace worn or damaged cab nets with new cab nets,
available from your authorized POLARIS dealer.
Storage Bag
The storage bag is attached
to the cab frame behind the
seats. Use the storage bag to
carry lightweight items such
as water bottles or apparel.
Do not carry heavy items in
the storage bag.
30
FEATURES AND CONTROLS
Fuel Cap
Never allow a child to refuel or
handle gasoline.
The fuel tank filler cap is located on
the right-hand side of the vehicle
near the passenger seat.
Use POLARIS Carbon Clean fuel
treatment at each fill. Follow the
Fuel Cap
mixing directions on the container.
See page 94 for the part numbers of
POLARIS products.
When refueling, always 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.
31
FEATURES AND CONTROLS
Ignition Switch
The ignition switch is a three-position, key-operated switch. Use the
ignition switch to start the engine. See page 40 for starting procedures.
The key can be removed from the switch when it is in the OFF position.
OFF
The engine is off. Electrical circuits are off, except accessory 12V.
ON
Electrical circuits are on. Electrical equipment can be used.
START
Turn the key to the START position to engage the electric starter.
The key returns to the ON position when released.
Ignition Switch
32
FEATURES AND CONTROLS
Gear Selector
F: Forward
N: Neutral
R: Reverse
The gear selector is located between
the seats. To change gears, stop the
vehicle, and with the engine idling,
move the lever to the desired gear.
Do not attempt to shift gears with
engine speed above idle or while the
vehicle is moving.
Gear Selector
Tip: Maintaining shift linkage adjustment is important to assure proper
transmission function. Your POLARIS dealer can assist in resolving any
shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.
Parking Brake
1. Apply the brakes.
2. When the vehicle is fully stopped, pull the parking brake lever
rearward as far as possible to set the parking brake.
3. Stop the engine.
4. To release the parking brake, apply the brakes and push the lever
toward the passenger seat and forward.
5. See page 64 for parking brake adjustment procedures.
Tip: Always set the parking brake whenever the vehicle is left unattended.
Operating the vehicle while the parking brake is engaged could cause an
accident resulting in serious injury or death. It could also result in driveline
or engine damage. Always be sure to disengage the parking brake before
operating the vehicle.
33
FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow
or stop the vehicle. Apply the
brakes while starting the engine.
Throttle Pedal
Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest
position when released. Always
check that the throttle pedal
Throttle
Brake
returns normally before starting
Pedal
Pedal
the engine. Make sure there's
adequate throttle pedal freeplay.
See page 70 for throttle pedal adjustment procedures.
This vehicle is equipped with a throttle release switch, 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 pedal, engine speed will be limited to idle speed.
The throttle release switch limits engine speed in the event of a throttle
system malfunction. Modifications to the throttle release switch 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 mechanism. Always ensure that the throttle cable is
installed and properly routed to the throttle control.
34
FEATURES AND CONTROLS
Speed Control System
This vehicle has an adjustable speed control system that controls engine
RPM and speed of the vehicle. The speed of this vehicle is restricted to
under 15 MPH (24 km/h) at manufacture. The speed limiting device
may be adjusted by supervising adults when they determine that their
child is capable of safely handling additional speed.
Electronic Speed Control System
Adjust speed by removing or installing the jumper wire on the terminals
located under the driver’s seat.
Jumper Condition
Installed
Removed
Restricted
Maximum Speed of Vehicle
15 MPH (24 km/h)
29 MPH (47 km/h)
1. Slide the driver’s seat forward
to access the jumper terminal.
2. Remove the two screws from
the jumper terminal to remove
or install the jumper wire.
3. Reinstall the screws.
4. Reposition the seat. Slide the
seat forward and rearward to
ensure the latch is engaged.
See page 26.
Jumper Terminal
Mechanical Speed Control System
Controlling speed electronically is the recommended method of speed
control, but the throttle stop can also be used. The adjustable throttle
limiting screw is located behind the throttle pedal. Use the following
procedure to control how far the throttle opens.
1. Loosen the jam nut.
2. Turn the screw outward to reduce speed. Turn the screw inward to
increase speed.
3. Tighten the jam nut after adjusting.
35
OPERATION
WARNING
Failure to operate the vehicle 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.
Vehicle Break-in Period
The break-in period for your new POLARIS vehicle is defined as 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 a proper break-in period.
Careful treatment of a new engine and drive components will result in
more efficient performance and longer life for these components.
Perform the following procedures carefully.
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.
Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or
mix oil brands.
36
OPERATION
Vehicle Break-in Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Always exercise extreme caution
whenever handling gasoline. Never allow a child to handle gasoline.
2. Check the oil level. See page 59. Add the recommended oil as
needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined on pages
42-43.
4. Avoid aggressive use of the brakes. See Brake System Break-in
below.
5. Vary throttle positions. Do not operate at sustained idle.
6. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 38.
7. Change the engine oil at 10 hours or one month.
8. Adjust and lubricate the drive chain at 10 hours or one month.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.
CVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Avoid
aggressive acceleration and high speed operation during the break-in
period.
37
OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item
Remarks
Page
Brake system/pedal travel
Ensure proper operation
34
71
Brake fluid
Ensure proper level
73
Front suspension
Inspect, lubricate if necessary
58
Rear suspension
Inspect, lubricate if necessary
58
Steering
Ensure free operation
74
Tires
Inspect condition and pressure
23
76
Wheels/fasteners
Inspect, ensure fastener tightness
77
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
Grass and debris
Remove grass and debris from the
vehicle, especially on the underside
and near the exhaust system
Throttle
Ensure proper operation
Indicator lights/switches
Ensure proper operation
Air filter
Inspect and clean or replace
67
Daytime running lights
Ensure proper operation
78
Brake light
Ensure proper operation
-
Seat Latches
Move the seats forward and rearward
to ensure correct installation
26
Seat Belts
Check length of belt for damage,
check latches for proper operation
28
Cab Nets
Check for wear or damage, ensure
proper installation
30
38
31
59
69
-
OPERATION
Safe Operation Practices
1. Complete the New Operator Driving Procedures outlined on pages
42-43.
2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your
vehicle doesn't have lights that are designed for driving in these
conditions.
3. Never tow objects or carry loads with this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area. Never allow a child to handle gasoline.
5. Never install accessories not approved by POLARIS for use on this
vehicle.
6. Ride this vehicle only in areas permitted by a supervising adult.
Never operate the vehicle on pavement or on any public street, road
or highway, including dirt and gravel roads.
7. Drive in a manner appropriate for your skills and operating
conditions. Never operate at excessive speeds. DO NOT attempt to
do power slides, “donuts”, jumps or other driving stunts. Keep both
hands on the steering wheel at all times.
8. Never consume alcohol or drugs before or while operating this
vehicle.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any rollover or accident,
have a qualified service dealer inspect the entire machine for
possible damage.
11. Never operate the vehicle 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.
39
OPERATION
Starting the Engine
1.
2.
3.
4.
5.
6.
Sit in the driver’s seat and fasten the seat belt.
Secure the cab nets.
Place the transmission in neutral. Set the parking brake.
Apply the brakes.
Do not press the throttle pedal while starting the engine.
Turn the ignition key past the ON/RUN position to START. Engage
the starter for a maximum of five seconds. Release the key 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.
7. If the engine does not start within five seconds, return the ignition
switch to the OFF position and wait five seconds. Repeat steps 6
and 7 until the engine starts.
8. Vary the engine RPM slightly with the throttle to aid in warm-up
until the engine idles smoothly.
9. Release the parking brake before driving.
40
OPERATION
Stopping the Engine
1.
2.
3.
4.
Release the throttle pedal completely and brake to a complete stop.
Place the transmission in neutral.
Set the parking brake.
Stop the engine.
Braking
1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the vehicle
has no engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and
stopping (using the brakes) until you're familiar with the controls.
Parking the Vehicle
1. Stop the vehicle on a level surface. When parking inside a garage or
other structure, be sure that the structure is well ventilated and that
the vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Stop the engine.
5. Remove the ignition key to prevent unauthorized use.
41
OPERATION
New Operator Driving Procedures
1. Read and understand this owner's manual and all warning and
instruction labels before operating this vehicle.
2. Watch the instructional video with the supervising adult.
3. Review the section of this owner’s manual about starting the engine,
stopping the engine, braking and parking (pages 40-41).
4. Perform the pre-ride inspection (page 38).
5. The driver and all passengers must wear helmet, eye protection,
gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat
belt at all times.
6. Do not operate or ride in this
vehicle if the clearance between
the top of your helmet and the
overhead cab frame is less than
Minimum
2 inches (5 cm).
2 inches
(5 cm)
(continued on next page)
42
OPERATION
New Operator Driving Procedures
7. Select a level open area to practice driving. Make sure you have
adult supervision and permission to drive in this area.
8. Sit in the driver's seat and fasten the seat belt.
9. Make sure all passengers secure their seat belts.
10. Make sure all cab nets are properly secured.
11. Do not carry a passenger until you have at least four hours of
driving experience with this vehicle. See page 44.
12. Set the parking brake.
13. Place the transmission in neutral.
14. Start the engine.
15. Apply the brakes and shift into gear.
16. Release the parking brake.
17. Check your surroundings. Make sure the area is clear of people and
obstacles.
18. Keeping both hands on the steering wheel, slowly release the brakes
and press the throttle with your right foot to begin driving.
19. Drive slowly at first. Practice starting, stopping, turning, using the
throttle and brakes and driving in reverse. Learn how the vehicle
handles when making both left and right turns at a slow speed.
20. Increase speed only after mastering all maneuvers at a slow speed.
21. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:
• Avoid sharp turns. Make turns gradually.
• Never turn while applying heavy throttle.
• Never turn the steering wheel abruptly.
• Operate at speeds appropriate for your skills, the conditions and
the terrain.
• DO NOT attempt to do power slides, “donuts”, jumps or other
driving stunts.
43
OPERATION
Driving with a Passenger
1. Complete the New
Operator Driving
Procedures outlined on
pages 42-43.
2. Perform the pre-ride
inspection. See page
38.
3. Do not carry a
passenger until you
have at least four hours
of driving experience
with this vehicle.
4. Never operate with a passenger under age 10. All riders must be
able to sit with backs against the seat, both feet flat on the floor and
both hands on the steering wheel (if driving) or on a passenger hand
hold.
5. Make sure the passenger has at least 2 inches (5 cm) of clearance
between his helmet and the top of the cab frame.
6. Never carry more than one passenger in this vehicle.
7. Never allow a passenger to ride on the back of the vehicle. Allow a
passenger to ride only in the passenger seat.
8. Make sure the passenger is wearing helmet, eye protection, gloves,
long-sleeve shirt, long pants and over-the-ankle boots. See page 10.
9. Make sure the passenger secures the seat belt.
10. Tell your passenger to always keep hands and feet inside the vehicle
at all times.
11. Make sure all cab nets are properly secured.
12. Drive slowly. Vehicle handling may change with a passenger on
board. Always travel at a speed appropriate for your skills, your
passenger's skills, and operating conditions. Avoid unexpected or
aggressive maneuvers that could cause discomfort or injury to a
passenger.
13. Always follow all operating guidelines as outlined on safety labels
and in this manual.
44
OPERATION
Driving on Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose gravel, sand
or ice, be alert for the possibility of skidding and sliding.
Follow these precautions when driving in slippery conditions:
1. Slow down before entering slippery areas.
2. Be alert, watch the path ahead and avoid quick turns, which can
cause skids.
3. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.
Sideways
skid
Turn in
direction of
skid
45
OPERATION
Driving Uphill
Whenever traveling
uphill, follow these
precautions:
1. Always check the
terrain carefully
before ascending a
hill. Never drive on
hills with
excessively slippery
or loose surfaces.
2. Avoid excessively
15° maximum
steep hills (15°
maximum).
3. Drive straight
uphill.
4. Drive at a steady rate of speed. Never press the throttle suddenly.
5. Avoid unnecessary changes in speed or direction.
6. Never go over the crest of a hill at a high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
7. If the vehicle stalls while climbing a hill, apply the brakes. Place the
transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying the brakes lightly to control speed.
46
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Driving on a sidehill
improperly cause loss of control or rollover.
If crossing a hill is unavoidable, follow these precautions:
1. Drive slowly and use extreme caution.
2. If the vehicle begins to roll over, or if it feels as if it may roll over,
immediately turn downhill.
3. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.
4. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and
carefully until the vehicle can be driven straight downhill.
Driving Downhill
Whenever driving down a hill, follow these precautions:
1. Avoid excessively steep hills (15° maximum).
2. Slow down. Never travel down a hill at high speed.
3. Always check the terrain carefully before driving down a hill. Never
drive on hills with excessively slippery or loose surfaces.
4. Always drive down a hill with the transmission in forward gear.
Never “coast” or drive down a hill with the transmission in neutral.
5. Avoid driving down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Always drive straight downhill.
6. Apply the brakes lightly to keep speed slow.
47
OPERATION
Driving Through Water
Your vehicle can drive through
shallow water. Make sure the
water is no deeper than the floor
of the vehicle. Follow these
precautions when driving
through water:
1. Check water depth. Never
drive through water that is
deeper than the floor level.
2. After driving through water,
test the brakes. Apply them
lightly several times while
driving slowly. The friction
will help dry out the pads.
Floor Level
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 53. Give special attention to engine oil,
transmission oil and all grease fittings.
If your vehicle becomes immersed or is operated in water that
exceeds the floor level, service is required before starting the engine.
Your POLARIS dealer can provide this service. If it's impossible to
bring the vehicle in before starting the engine, perform the service
outlined on page 79, and take the vehicle in for service at the first
opportunity.
48
OPERATION
Driving Over Obstacles
Follow these precautions when driving over obstacles:
1. Always check for obstacles before driving in a new area.
2. Look ahead and watch the terrain. Always be alert for hazards such
as logs, rocks and low hanging branches.
3. Drive slowly and use extra caution when driving on unfamiliar
terrain. Obstacles are not always clearly visible.
4. Do not drive over large obstacles such as large rocks and fallen
trees. If it’s unavoidable, use extreme caution and drive slowly.
5. Always have a passenger dismount and move away from the vehicle
before driving over an obstacle that could cause a rollover.
49
OPERATION
Driving in Reverse
Follow these precautions when driving in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply the throttle suddenly.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.
50
OPERATION
Parking on an Incline
A rolling vehicle can result in serious injury. Avoid parking on an
incline. If parking on an incline is unavoidable, follow these
precautions:
1. Place the transmission in neutral.
2. Set the parking brake.
3. Stop the engine.
4. Always block the rear wheels on the downhill side.
51
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
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI
components are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on the frame behind the right front wheel.
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.
52
MAINTENANCE
Periodic Maintenance Chart
Any qualified repair shop or person may maintain, replace or repair the
emission control devices or systems on your vehicle. An authorized
POLARIS dealer can perform any service that may be necessary for
your vehicle. POLARIS also recommends POLARIS parts for
emissions-related service, however equivalent parts can be used.
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.
Owners are responsible for performing the scheduled maintenance
identified in this owner’s manual.
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, genuine POLARIS
parts are available from your POLARIS dealer. Equivalent parts may be
used for emissions-related service.
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, a
qualified dealer can perform these operations.
Vehicles subjected to heavy or severe use patterns 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 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. Your POLARIS dealer can assist.
53
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
Symbol
Description
Ź
Perform these operations more often for vehicles subjected to severe use.
D
Have an authorized POLARIS dealer or other qulaified person 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 or other qualified person perform these services.
54
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
Steering
-
-
Front suspension
-
-
Rear suspension
-
-
Tires
-
Brake fluid level
-
Daily
-
Brake pedal travel
-
-
Brake system
-
-
Wheels/fasteners
-
-
Frame fasteners
-
-
Engine oil level
-
-
Ź Air filter
Remarks
Check each day before
driving the vehicle. Make
adjustments as needed.
See the Pre-Ride Checklist
on page 38.
-
Daily
-
Inspect; clean often; replace
as needed
Daytime running
lights/taillight
-
Daily
-
Check operation
Drive chain
-
Daily
-
Inspect daily; adjust and
lubricate if needed
CVT housing (if
equipped)
-
Weekly
-
Drain water as needed,
check often if driving in wet
conditions
Ź Brake pad wear
D
10
Monthly
100 (160)
Ź Engine oil change
(break-in)
10
1M
-
Perform a break-in oil change
at one month
Drive chain
(break-in)
10
1M
-
Adjust and lubricate
Fuel System
25
Monthly
-
Inspect; cycle key to
pressurize fuel pump; check
lines and fittings for leaks and
abrasion
25
Monthly
250 (400)
Check terminals; clean; test
25
Monthly
250 (400)
Inspect level; change yearly
Battery
Ź Main gearcase oil
Inspect periodically
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
55
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Ź Engine breather
filter (if equipped)
25
Monthly
150 (250)
Inspect; replace if necessary
Ź Engine oil change
30
6M
300 (480)
Perform a break-in oil change
at one month
Ź General
lubrication
50
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
D Throttle release
switch
50
6M
300 (480)
Inspect; adjust; lubricate;
replace if necessary
Shift Linkage
Inspect, lubricate, adjust
50
6M
500 (800)
D Steering
50
6M
500 (800)
Lubricate
Ź Front Suspension
50
6M
500 (800)
Lubricate
Lubricate
Ź Rear Suspension
50
6M
500 (800)
D Fuel system/filter
100
12 M
600 (1000) Cycle key to pressurize fuel
pump; check for leaks at fill
cap, fuel lines/rail and fuel
pump; replace lines every
two years
Ź Spark plug
100
12M
600 (1000) Inspect; replace as needed
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
.
56
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Hours Calendar
Ź Engine mounts
Exhaust muffler/
pipe
Remarks
(whichever comes first)
Miles
(Km)
100
12 M
1000 (1600) Inspect
100
12 M
1000 (1600) Inspect
D Ignition timing
100
12 M
1000 (1600) Inspect
Ź Wiring
100
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
12 M
1000 (1600) Inspect; clean; replace worn
parts
Drive belt
100
12 M
1000 (1600) Inspect; replace as needed
D Front wheel
bearings
100
12 M
1000 (1600) Inspect; replace as needed
D Brake fluid
200
24 M
2000 (3200) Change every two years
300
36 M
3000 (4800) Clean out
Spark arrester
D Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
57
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item
Engine Oil
Brake Fluid
Transmission Oil
(Main Gearcase)
Drive Chain
A-Arm Pivots
Ź Steering Arm
Pivots
Lube
PS-4 Extreme Duty
10W-50 4-Cycle Oil
DOT 4 Brake Fluid
AGL Gearcase Lubricant
& Transmission Fluid
POLARIS Chain Lube or
SAE 80/90
POLARIS All Season
Grease or grease
conforming to NLGI No. 2
Method
See page 59.
See page 73.
See page 61.
See page 62.
Grease at general lubrication
interval, also after washing
vehicle or driving in water.
ŹPerform these procedures more often for vehicles subjected to severe use.
A-Arm Pivots
Steering Arm
Pivots
58
MAINTENANCE
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53. POLARIS
recommends the use of POLARIS PS-4 Extreme Duty 10W-50 4-Cycle
Oil for this vehicle. Oil may need to be changed more frequently if
POLARIS oil is not used. Do not use automotive oil. See page 94 for the
part numbers of POLARIS products.
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 Check
Maintain the oil level within the
safe range on the dipstick. Do not
overfill.
1. Position the vehicle on a level
surface.
2. Remove the dipstick. Wipe it
dry with a clean cloth.
3. Reinstall the dipstick
completely.
4. Remove the dipstick and
check the oil level.
5. Add the recommended oil as
needed.
6. Reinstall the dipstick.
Safe Range
{
Tip: A rising oil level between checks
in cool weather driving can
indicate contaminants such as
gas or moisture collecting in the
crankcase. If the oil level is over
the full/safe mark, change the oil
immediately.
Dipstick
Add Oil
Full
59
MAINTENANCE
Engine Oil
Oil Change
1.
2.
3.
4.
Position the vehicle on a level surface. Set the parking brake.
Clean the area around the pre-filter plug.
Start the engine. Allow it to idle for two to three minutes.
Stop the engine.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Place a drain pan under the
engine crankcase.
6. Remove the pre-filter plug.
Allow the oil to drain completely.
7. Wash the oil pre-filter screen with solvent to remove debris. Allow
the screen to air dry.
8. Clean the pre-filter plug. Install a new sealing washer on the plug.
The sealing surfaces on the plug and crankcase should be clean and
free of burrs, nicks or scratches.
9. Reassemble the pre-filter screen and spring to the pre-filter plug.
10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm).
11. Remove the dipstick. Add 37 oz. (1.1 liters) of the recommended
oil. Do not overfill. See the specifications section beginning on
page 92 for capacities.
12. Reinstall the dipstick.
13. Start the engine. Allow it to idle for one to two minutes.
14. Stop the engine and inspect for leaks.
15. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
16. Dispose of used oil properly.
60
MAINTENANCE
Transmission (Main Gearcase)
Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53. POLARIS
recommends the use of AGL Gearcase Lubricant & Transmission Fluid
for this vehicle.
Fluid Check
Fill Plug
The fill plug is located on the rear of the
gearcase. Access the fill plug through the
left rear wheel well. Maintain the fluid
level at the bottom of the fill plug hole.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid as
needed.
5. Reinstall the fill plug.
Fluid Change
The drain plug is located on the bottom of the gearcase.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to 11 ft. lbs. (15
Nm).
6. Add 23.7 oz. (700 ml) of the recommended fluid to the fill hole.
Maintain the fluid level at the bottom of the fill plug hole. Do not
overfill.
7. Reinstall the fill plug.
8. Check for leaks.
9. Discard used fluid properly.
61
MAINTENANCE
Drive Chain Lubrication
Lubricate the drive chain with POLARIS chain spray lube or an
approved chain lube at the general lubrication interval specified in the
Periodic Maintenance Chart beginning on page 53. Lubricate more often
under severe use, such as in dirty or wet conditions. See page 94 for the
part numbers of POLARIS products.
NOTICE: Washing the drive chain with a high pressure washer or gasoline can
cause premature wear and drive chain failure. Don't use a high
pressure washer or gasoline to clean the drive chain.
Adjusting or operating the vehicle with improper rear drive chain slack
can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Drive Chain Slack
1. Check the amount of chain
slack by moving the vehicle
slightly forward to gain slack
at the top side of the chain.
2. Raise the rear of the vehicle
and support securely under
the mainframe. Allow the
swing arm to hang at full
shock extension without
touching the ground. This
establishes the tightest chain
position.
3. Pull down on the chain tensioner to move it out of the
way, then measure chain
slack. It should have 1/4"-1/2"
(6-12 mm) deflection.
4. If the chain needs adjustment,
use the procedure on page 63.
62
Chain
Tensioner
MAINTENANCE
Drive Chain Slack Adjustment
1. Loosen the four rear housing
mount bolts (two on each side).
2. Loosen the chain adjuster lock
nuts.
3. Turn the chain adjusters clockwise
to 1/4"-1/2" (6-12 mm) deflection.
4. Tighten the chain adjuster lock
nuts to 18 ft. lbs. (25 Nm). Hold
the adjuster stud securely while
tightening the nut to avoid
breaking the stud.
5. Tighten the four rear housing
mount bolts to 43 ft. lbs. (60 Nm).
Housing Mount Bolts
Chain Adjusters
63
MAINTENANCE
Parking Brake Cable Freeplay Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting parking brake cable freeplay.
2. Make sure the parking brake is NOT set (lever is DOWN).
3. Pull the brake cable back to inspect freeplay between the cable end
and the caliper bracket. Freeplay should be 1/16" - 1/8" (1.5-3 mm).
4. To adjust freeplay,
loosen the jam nut.
Turn the in-line
adjuster nut outward to
decrease freeplay. Turn
the adjuster nut inward
to increase freeplay.
Jam
In-line
Inspect
5. Tighten the jam nut
Nut
Adjuster Nut
Freeplay
against the adjuster nut.
Parking Brake Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting the parking brake.
2. Position the vehicle on a level surface. Place the transmission in
neutral.
3. Carefully elevate the rear of the vehicle slightly. Use an appropriate
lift.
4. Loosen the jam nut on the parking
brake adjustment bolt.
5. While rotating the rear wheels by
hand, tighten the adjustment bolt
until significant brake drag is
detected. Then back the adjustment
bolt out 1/4 turn.
6. Hold the adjustment bolt in place
and tighten the jam nut securely
Adjustment Bolt
Jam Nut
against the lever arm.
7. Check parking brake lever movement. Verify that the rear wheels
rotate freely with the parking brake off (lever in DOWN position)
and that the vehicle will not move when the parking brake is applied
(lever in UP position).
8. Verify that the park brake lever stays in the UP position when the
brake is fully applied.
64
MAINTENANCE
Spark Plug
Spark Plug Gap/Torque
Electrode Gap
0.6-0.7 mm
New Plug Torque
9-11 ft. lbs.
(12-15 Nm)
Used Plug Torque
17-20 ft. lbs.
(23-27 Nm)
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Use POLARIS-recommended spark plugs or their
equivalent. See page 92.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 65.
A hot exhaust system and engine can cause burns. Wear protective
gloves when removing a spark plug for inspection.
Spark Plug Condition
Normal 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.
Tip: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled 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 injection oil or incorrect throttle body
adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the spark plug wrench provided
in the tool kit, remove the plug by
rotating it counter-clockwise.
3. Reverse the procedure for spark plug
installation. Torque to specification.
See page 65.
Spark Plug
(right rear wheel well)
65
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 POLARIS
dealer, or other qualified person, for service and repair assistance.
• 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. The drain plug is located on the bottom of the CVT cover.
1. Remove the drain plug. Allow the water to drain. Reinstall the drain
plug.
2. Shift the transmission to neutral. Set the parking brake.
3. Start the engine. 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.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Your vehicle requires service as soon as possible. Your POLARIS
dealer can assist.
NOTICE: Exposure to salt water will cause corrosion to metal components. If
your vehicle is operated in salt water areas, rinse it off frequently with
fresh water.
66
MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the
intervals outlined in the Periodic
Maintenance Chart beginning on page 53.
Access the air box through the access
cover on the forward surface of the rear
body panel.
1. Move or remove the storage bag.
Remove the four (4) access cover
fasteners to remove the access cover.
2. Release the air box cover spring clips
and remove the cover.
3. Loosen the air filter clamp. Remove
the air filter.
4. Clean away any oil or sediments in
the air box.
5. Apply a commercially available
chassis lubricant to the inside lip of
the new air filter. Install the filter and
tighten the clamp.
6. Reinstall the air box cover and secure
the clips.
Access Cover
Filter
Lubricant
NOTICE: Never operate the vehicle with the
filter element removed. Dirt will enter
the engine, causing rapid wear and
severe damage to the engine.
7. Reinstall the access cover and storage
bag.
67
MAINTENANCE
Spark Arrester
WARNING
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death.
• Do not perform service on the spark arrester while the system is hot. Allow
components to cool sufficiently before proceeding.
• Wear eye protection and gloves.
• Never operate without the spark arrestor.
• Never run the engine in an enclosed area. Exhaust contains poisonous carbon
monoxide gas.
To remove accumulated carbon, clean the spark arrester at the intervals
recommended in the Periodic Maintenance Chart beginning on page 53.
1. Remove the six bolts 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,
Arrester Screen
blow debris from the
screen with compressed
air.
3. Inspect the screen for wear and damage. Replace the arrester if damage is found.
4. Reinstall the arrester.
5. Torque the bolts to 7 ft. lbs. (9.5 Nm).
68
MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result in
an accident and lead to serious injury or death if the throttle pedal sticks during
operation.
Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal.
Immediately contact your POLARIS dealer or other qualified person for service if
throttle problems arise.
Always check the pedal for free movement and return before starting the engine
and occasionally during operation.
Throttle Freeplay
If the throttle pedal has excessive
play due to cable stretch or misadjustment, it will cause a delay in
throttle response, especially at low
engine speed. The throttle may
also not open fully. If the throttle
pedal has no freeplay, the throttle
may be hard to control, and the
idle speed may be erratic.
Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 53. Adjust the
freeplay if necessary.
Brake
Pedal
Throttle
Pedal
Throttle Freeplay Inspection
1. Place the transmission in neutral. Set the parking brake.
2. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.53 mm).
69
MAINTENANCE
Throttle System
Throttle Freeplay Adjustment
Access the throttle cable
adjuster through the right front
wheel well.
1. Slide the cable adjuster
boot off the cable adjuster.
2. Squeeze the end of the
rubber boot and slide it far
enough to expose the end
of the inline cable adjuster.
3. Loosen the adjuster lock
nut.
4. Move the cable adjuster
until 1/16" to 1/8" (1.5-3
mm) of freeplay is
achieved at the throttle
pedal. See page 69. While
adjusting, lightly flip the
throttle pedal up and down.
5. Tighten the lock nut.
6. Apply a small amount of
grease to the inside of the
boot and slide it over the
cable adjuster to its
original position.
70
Boot
Lock Nut
Adjuster
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 34.
Always check brake pedal travel and the brake fluid reservoir level
before each use of the vehicle. When applied, the brake pedal should
feel firm. Any sponginess would indicate a possible fluid leak or low
brake fluid level, which must be corrected before riding. See page 73 for
brake fluid information.
If you discover any irregularities in brake system operation, including
excessive pedal travel, contact your dealer for proper diagnosis and
repairs.
Operating the vehicle with a spongy brake pedal can result in loss of
braking, which could cause an accident resulting in severe injury or death.
Never operate the vehicle with a spongy-feeling brake pedal.
71
MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system
for fluid leaks.
2. Check the brake pedal
for excessive travel or a
spongy feel.
Brake Pad
3. Check the brake pads for
wear, damage and
.40" (1 mm)
looseness.
4. Inspect the brake pad
wear surface for
excessive wear.
5. Change pads when the
friction material is worn
to .40" (1 mm).
6. Check the surface
Front Disc
Rear Disc
condition of the brake
discs. Measure the
thickness of the front and
.170" (4.32 mm)
rear discs. Replace a disc
if the thickness is less than .170” (4.32 mm).
7. Check brake system hoses and fittings for cracks, deterioration,
abrasion and leaks. Tighten any loose fittings and replace any worn
or damaged parts.
72
MAINTENANCE
Brakes
Brake Fluid
Inspect the level of the brake fluid before each operation. If the fluid
level is low add DOT 4 brake fluid only. See page 94 for the part
numbers of POLARIS products.
After opening a bottle of brake fluid, always discard any unused portion.
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of accident or severe injury.
Change the brake fluid every two
Maximum
Brake Fluid
years and any time the fluid
Reservoir
Minimum
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown.
Access the brake fluid reservoir
through the left front wheel well.
1. Position the vehicle on a level
surface.
2. Place the transmission in
neutral. Set the parking
brake.
3. View the brake fluid level in
the reservoir. The level
should be between the
maximum and minimum
level lines. Add brake fluid as needed.
4. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
73
MAINTENANCE
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 53.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8"-1.0" (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels
rough or "catchy," have the steering system inspected by an
authorized POLARIS dealer or other qualified service facility
before operating the vehicle.
Shock Spring Adjustment
The front and rear shock absorber springs are adjustable to increase or
decrease spring tension. Rotate the adjuster either clockwise or counterclockwise to make adjustments. Always apply the same adjustment
setting to all four wheels.
WARNING! Uneven adjustment may cause poor handling of the vehicle, which
could result in an accident. Always adjust both the left and right spring preloads
equally or have your POLARIS dealer perform the adjustments.
Adjustment
Cam
Highest (Stiffest)
Setting
74
Lowest (Softest)
Setting
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" (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 or other qualified
service facility.
1. Position the vehicle on a
level surface.
2. Set the handlebars in a
straight-ahead position
and secure them in this
position.
2
3. Place a chalk mark on the
center line of the front
1
tires approximately 10"
(25.4 cm) from the 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 to rotate the tires 180°. Position the wheels with
the chalk marks 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.
75
MAINTENANCE
Tires
WARNING
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. Always use POLARISapproved size and type of tires for this vehicle when replacing tires.
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 or other qualified service facility.
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in neutral. Set the parking brake. Stop the
engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by placing a suitable stand under the
frame.
5. Remove the wheel nuts. Remove the wheel.
76
MAINTENANCE
Tires
Wheel Installation
1. Place the
transmission in
neutral.
2. Set the parking
brake.
3. Place the wheel on
the wheel hub with
the valve stem
toward the outside
and the rotation
arrows on the tire
pointing toward
forward rotation.
4. Attach the wheel
nuts and finger tighten.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure that
all nuts are torqued to specification. Do not service axle nuts that have a
cotter pin installed. Your POLARIS dealer can assist.
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)
77
MAINTENANCE
Lights
Daytime Running Lights Lamp Replacement
If the daytime running lights do not operate, replace the lamps.
POLARIS recommends that you install replacement lamps obtained
from your authorized POLARIS dealer.
1. Disconnect the lights from the harness.
2. Remove the rubber cover from the back of the light assembly.
3. Press the lamp retainer inward and turn it counter-clockwise to
remove it. Note the position of the lamp positioning tab, then
carefully pull the lamp out.
4. Install the new lamp. Make sure the filament is horizontal.
5. Reinstall the lamp retainer. Press the retainer inward and turn it
clockwise about 1/4 turn.
6. Start the engine to make sure the lights come on. If the lights do not
operate, see your POLARIS dealer for service.
7. Reinstall the rubber cover, and reconnect the lights to the harness.
Tail Light Lamp Replacement
If the brakelight doesn't work, the
lamp may need to be replaced.
1. Remove the two screws
securing the lens cover.
Remove the lens cover.
2. Remove the lamp and replace
it with a new recommended
lamp.
3. Test the light for proper
operation.
4. Reinstall the lens cover.
78
Lamp
Cover
Screws
MAINTENANCE
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle in for
service before starting the engine. Your POLARIS dealer can provide
this service.
If it’s impossible to take your vehicle to a dealer before starting it,
follow the steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter. Thoroughly dry the air pre-filter. See page
67.
3. Remove the air box drain plug to drain any water. Reinstall the drain
plug securely.
4. Remove the spark plug.
5. Turn the engine over several times using the electric start.
6. Dry the spark plug and reinstall it, or install a new plug.
7. Attempt to start the engine. If necessary, repeat the drying
procedure.
8. Take the vehicle in for service as soon as possible, whether you
succeed in starting it or not. Your POLARIS dealer can provide the
required service.
9. If water has been ingested into the transmission follow the
procedure on page 66 for drying.
79
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 vehicle 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 the 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.
80
MAINTENANCE
Battery
Battery Removal
1. Remove the driver’s seat. See
Remove Seat
page 26.
2. On conventional batteries,
remove the battery vent tube
(sealed batteries do not have a
vent tube).
3. Disconnect the black (negative)
battery cable first.
4. Disconnect the red (positive)
battery cable last.
Battery
5. Lift the battery out of the
vehicle. 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.
81
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 84 before
installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery 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.
Battery gases could accumulate in an improperly installed vent tube and
cause an explosion, resulting in serious injury or death. Always ensure
that the vent tube is free of obstructions and is securely installed as
recommended.
4.
5.
6.
7.
8.
82
Coat the terminals with dielectric grease or petroleum jelly.
Connect and tighten the red (positive) cable first.
Connect and tighten the black (negative) cable last.
Verify that cables are properly routed.
Reinstall the driver’s seat.
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.
See page 84.
Tip: Battery charge can be maintained by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal selfdischarge. Battery Tender can be left connected during the storage period,
and will automatically charge the battery if the voltage drops below a predetermined point. See page 94 for the part numbers of POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the
battery fluid level often. Maintain
the fluid level between the upper
and lower level marks.
Add only distilled water. Tap water
contains minerals that are harmful
to a battery.
Lower
Mark
Upper
Mark
83
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 81.
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 82. 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.
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
Charging Harness
is 12.8 or greater. The battery
charging harness is located under
the left edge of the driver’s seat.
Connect the battery charging harness to the charger.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
guidelines on the next page for recharging.
84
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
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
85
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.
Before washing the vehicle, locate the CVT
inlet and outlet ducts. The ducts are located
under the rear wheel wells. Avoid spraying
water directly toward the ducts when
washing the vehicle from the rear.
NOTICE: Water in the CVT system could cause
the drive belt to become wet and slip in
the clutches. Always avoid spraying
water directly toward the CVT inlet and
outlet ducts when washing the vehicle
from the rear.
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.
86
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 labels. Avoid directing the water stream at the
following items:
• Wheel bearings
• Radiator
• Transmission seals
• CVT inlet and outlet ducts
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
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.
87
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.
Tip: 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.
88
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 86.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer or equivalent fuel treatments or stabilizers. 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 entire fuel delivery system.
Air Filter / Air Box
Inspect and clean or replace the air filter. See page 67. Clean the air box.
Drain the sediment tube.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 53.
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
Engine Oil
Change the oil. See page 60.
89
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 53.
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean or other
equivalent fuel treatment. Follow the instructions on the container.
Start the engine. Allow it to idle for several minutes so the Carbon
Clean reaches the injectors. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To
access the plug hole, use a section of clear 1/4” hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
3. Reinstall the spark plug. Torque to specification. See page 65.
4. Apply dielectric grease to the inside of the spark plug cap. Do not
reinstall the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a
protective film of fresh oil.
6. If fuel system additive is not used, fuel tank, fuel lines, and injectors
should be completely drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
Battery Maintenance
See pages 83-85 for storage and charging procedures.
Storage Area/Covers
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.
90
MAINTENANCE
Cleaning and Storage
Removal from Storage
1. Check the battery electrolyte level and charge the battery if
necessary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 38. Tightness of the bolts, nuts and other fasteners should
be checked by an authorized POLARIS dealer or other qualified
service facility.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 53.
Transporting the Vehicle
Follow these procedures when
transporting the vehicle.
1. Place the transmission in neutral. Set
the parking brake.
2. Stop the engine.
3. Remove the key to prevent loss
during transporting.
4. Secure the fuel cap and seats. Ensure
that the seats are attached correctly
and are not loose.
NOTICE: Always tie the frame of the
POLARIS vehicle to the
transporting unit securely with
suitable straps or rope. Do not
attach tie straps to the front control
arm bolt pockets.
5. Wrap the front tie strap through the
frame tubes, or attach a tie-down
hook around each of the tubes.
6. Wrap the rear tie strap around the
swing arm.
Tubes
Step 5
Step 5
Step 6
91
SPECIFICATIONS
RZR 170
Maximum Rider Weight
Maximum Weight Capacity
Gross Vehicle Weight
Dry Weight
Fuel Capacity
Engine Oil Capacity
Transmission Oil Capacity
Overall Length
Overall Width
Overall Height
Wheelbase
Ground Clearance
Engine Type
Displacement
Cooling
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Throttle Body Size
Ignition System
Ignition Timing
Spark Plug / Gap
Front Suspension
Rear Suspension
Lubrication System
Driving System Type
Final Drive
Shift Type
92
150 lbs. (68 kg) (each rider)
300 lbs. (81.7 kg)
840 lbs. (381 kg)
500 lbs. (227 kg)
2.5 gal. (9.5 ltr)
37 oz. (1.1 ltr)
23.7 oz. (700 ml)
85 in. (216 cm)
48 in. (122 cm)
55 in. (139.7 cm)
65 in. (165 cm)
6 in. (15.2 cm)
4-Stroke
169 cc
Air Cooled
61 mm x 57.8 mm
80 watts
9.5:1
Electric
Electronic fuel injection
36 mm
CDI
32° +/- 2° @ 5000 RPM
NGK CR6HSA / 0.6-0.7 mm
Single A-arm w/5 in. (12.7 cm) travel
Dual Shock swing arm w/5 in. (12.7 cm) travel
Wet Sump
Automatic Constant Variable Transmission
Chain
F/N/R
SPECIFICATIONS
RZR 170
Tire Size - Front
Tire Size - Rear
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Parking Brake
Daytime Running Lights
Brake Light
19x7-8
20x10-9
3 psi (20.7 kPa)
3 psi (20.7 kPa)
Foot Activated, 4-wheel hydraulic disc
Mechanical, Rear (Lever)
Dual, Standard
Standard
Clutching Chart
To access clutches for inspection, remove the passenger seat and remove the
clutch access panel. See page 26.
ALTITUDE
Meters (Feet)
0-3048 (0-10,000)
Above 3048 (Above 10,000)
SHIFT WEIGHT
6 @ 17 grams
*6 @ 15 grams
PN 0454619
*Optional 15-gram weight
93
POLARIS PRODUCTS
Part
Description
Number
Engine Lubricant
2870791
Fogging Oil (12 oz. Aerosol)
2878920
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068
AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (qt./.95 l)
2878069
AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (gal./3.8 l)
2872348
Chain Lube, Aerosol
Grease / Specialized Lubricants
2871312
Grease Gun Kit, All Season Grease
2871322
All Season Grease (3 oz./89 ml cartridge)
2871423
All Season Grease (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326
Carbon Clean
2870652
Fuel Stabilizer
2872189
DOT 4 Brake Fluid
2871956
Loctite™ 565 Thread Sealant
2859044
POLARIS Battery Tender™ Charger
94
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause
Solution
Driving at low RPM or
ground speed
Drive at a higher speed.
Insufficient warm-up at
low ambient temperatures
Warm the engine at least 5 minutes. With the transmission
in neutral, apply small amount of throttle in short bursts, 5
to 7 times. The belt will become more flexible and
prevent belt burning.
Slow/easy clutch engage- Use the throttle quickly and effectively.
ment
Belt slippage from water
or snow ingestion into the
CVT system
Dry out the CVT (see page 66). Prevent water from
entering the CVT inlet and outlet ducts (see page 86).
Inspect clutch seals for damage if repeated leaking
occurs.
Clutch malfunction
Your POLARIS dealer can assist.
Poor engine performance
Check for fouled plug or foreign material in gas tank or
fuel lines. Your POLARIS dealer can assist.
Wrong or missing belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch. See page 36.
95
TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Low battery voltage
Loose battery connections
Loose solenoid connections
Solution
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plug
No spark to spark plug
Water or fuel in crankcase
Clogged fuel filter
Low battery voltage
Mechanical failure
Solution
Refuel
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plug and replace if necessary
Inspect plug and replace if necessary
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Recharge the battery to 12.8 VDC
Your POLARIS dealer can assist.
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Loose ignition connections
Water present in fuel
Exhaust system leak
96
Solution
Inspect, clean and/or replace spark plug
Set gap to specs or replace plug
Replace with fresh recommended fuel
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Check all connections and tighten
Replace with fresh recommended fuel
Your POLARIS dealer can assist.
TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Solution
Replace with recommended fuel
Your POLARIS dealer can assist.
Set gap to specs or replace plug
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plug
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
Electronic throttle control malfunction
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Low octane fuel
Clogged fuel filter
Incorrect fuel
Possible Rich Fuel Cause
Fuel is very high octane
Stopping/starting without adequate
warm-up
Incorrect fuel
Clogged air filter
Solution
Inspect, clean and/or replace spark plug
Your POLARIS dealer can assist.
Set gap to specs or replace plug
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
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Solution
Add or change fuel, clean the fuel system
Replace with recommended fuel
Your POLARIS dealer can assist.
Replace with recommended fuel
Solution
Replace with lower octane fuel
Allow engine to warm up before operating and/or stopping
Replace with recommended fuel
Inspect and clean or replace
97
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plug
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Incorrect fuel
Clogged air filter
Electronic throttle control malfunction
Other mechanical failure
98
Solution
Refuel
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark plug
Your POLARIS dealer can assist.
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
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
WARRANTY
LIMITED WARRANTY
POLARIS Industries 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
arrester 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 racing, competition or 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
Warranty Coverage And Exclusions:
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
Filters
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 CONSEQUENTIAL,
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. POLARIS 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 Form to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use
your original selling dealer; however, you may use any POLARIS Servicing Dealer to
perform warranty service.
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.
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.
101
WARRANTY
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 (1550 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.
Emission-related components also include any other part whose only purpose is to
reduce emissions or whose failure will increase emissions without significantly
degrading engine/equipment performance. 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. An authorized POLARIS dealer can perform
any service that may be necessary for your vehicle. POLARIS also recommends
POLARIS parts, however equivalent parts may be used for such service. 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 “B” in the ninth position of the
model number (e.g., R16RTE87B). 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
Use the following chart to record periodic maintenance.
DATE
106
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
107
INDEX
A
Adjustment, Steering Wheel . . . . . .
Adjustment, Throttle Freeplay. . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . .
Air Filter Cleaning. . . . . . . . . . . . . .
Arrester, Spark, Warning. . . . . . . . .
D
27
70
67
67
68
B
Battery . . . . . . . . . . . . . . . . . . . . 80-85
Battery Charging . . . . . . . . . . . . . 84-85
Battery Fluid Replenishment . . . . . . 83
Battery Installation. . . . . . . . . . . . . . 82
Battery Removal . . . . . . . . . . . . . . . 81
Battery Storage . . . . . . . . . . . . . . . . 83
Before Riding. . . . . . . . . . . . . . . . . . 38
Belt Burning. . . . . . . . . . . . . . . . . . . 95
Belt Wear . . . . . . . . . . . . . . . . . . . . . 95
Belts, Seat . . . . . . . . . . . . . . . . . . 28-29
Boots . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Adjustment, Parking . . . . . . . 64
Brake Adjustment . . . . . . . . . . . . . . 64
Brake Fluid . . . . . . . . . . . . . . . . . . . 73
Brake Inspection . . . . . . . . . . . . . . . 72
Brake Pedal . . . . . . . . . . . . . . . . . . . 34
Brake System Break-in . . . . . . . . . . 37
Brakes . . . . . . . . . . . . . . . . . . . . . 71-73
Braking . . . . . . . . . . . . . . . . . . . . . . 41
Break-In Period . . . . . . . . . . . . . . 36-37
Burning Belts . . . . . . . . . . . . . . . . . . 95
Drive Belt Wear. . . . . . . . . . . . . . . . . 95
Drive Chain Lubrication . . . . . . . . . . 62
Drive Chain Slack . . . . . . . . . . . . . . . 62
Drive Chain Slack Adjustment . . . . . 63
Drivetrain Break-In . . . . . . . . . . . . . . 37
Driving Downhill. . . . . . . . . . . . . . . . 47
Driving in Reverse. . . . . . . . . . . . . . . 50
Driving on a Sidehill . . . . . . . . . . . . . 47
Driving on Slippery Surfaces . . . . . . 45
Driving Over Obstacles . . . . . . . . . . . 49
Driving Procedures . . . . . . . . . . . 42-43
Driving Through Water . . . . . . . . . . . 48
Driving Uphill . . . . . . . . . . . . . . . . . . 46
Driving with a Passenger. . . . . . . . . . 44
E
C
Electromagnetic Interference. . . . . . . 52
Emission Control, Crankcase . . . . . . 52
Emission Control, Exhaust . . . . . . . . 52
Emission Control, Noise . . . . . . . . . . 52
Emissions Limited Warranty . . 103-105
Engine Break-In. . . . . . . . . . . . . . . . . 37
Engine Fogging . . . . . . . . . . . . . . . . . 90
Engine Oil . . . . . . . . . . . . . . . . . . 59-60
Engine Stopping . . . . . . . . . . . . . . . . 41
Equipment Modifications . . . . . . . . . . 9
Exhaust Cleaning. . . . . . . . . . . . . . . . 68
Exhaust Emission Control System . . 52
Exhaust System Warning. . . . . . . . . . 68
Eye Protection . . . . . . . . . . . . . . . . . . 11
Cab Nets. . . . . . . . . . . . . . . . . . . . . . 30
Changing Gears . . . . . . . . . . . . . . . . 33
Chart, Periodic Maintenance . . . . 53-57
Chrome Wheel Care . . . . . . . . . . . . 88
Cleaning and Storage. . . . . . . . . . 86-91
Cleaning the Air Filter . . . . . . . . . . . 67
Cleaning, Exhaust System . . . . . . . . 68
Cleaning, Spark Arrester . . . . . . . . . 68
Clothing . . . . . . . . . . . . . . . . . . . . . . 11
Clutching Chart . . . . . . . . . . . . . . . . 93
Component Locations . . . . . . . . . 24-25
Condition, Spark Plugs . . . . . . . . . . 65
Constant Variable Transmission . . . 66
Corrosion Removal, Chrome . . . . . . 88
Cover for Storage. . . . . . . . . . . . . . . 90
Crankcase Emission Control System 52
CVT Break-In . . . . . . . . . . . . . . . . . 37
CVT Drying . . . . . . . . . . . . . . . . . . . 66
CVT System. . . . . . . . . . . . . . . . . . . 66
Filling the Battery . . . . . . . . . . . . . . . 83
Filter Care During Storage . . . . . . . . 89
Filter Cleaning, Air . . . . . . . . . . . . . . 67
Filter Systems . . . . . . . . . . . . . . . . . . 67
Filter, Air . . . . . . . . . . . . . . . . . . . . . . 67
Fluid
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission. . . . . . . . . . . . . . . . . 61
Fluid Change
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission. . . . . . . . . . . . . . . . . 61
Fluid Check
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission. . . . . . . . . . . . . . . . . 61
Fluid Levels During Storage . . . . . . . 89
Fluid, Battery . . . . . . . . . . . . . . . . . . . 83
Fluid, Brake . . . . . . . . . . . . . . . . . . . . 73
108
F
INDEX
F
Fogging the Engine . . . . . . . . . . . . . .
Fouled Plugs . . . . . . . . . . . . . . . . . . .
Freeplay Adjustment, Throttle . . . . .
Freeplay, Steering Wheel . . . . . . . . .
Fuel Cap . . . . . . . . . . . . . . . . . . . . . .
Fuel Safety . . . . . . . . . . . . . . . . . . . .
Fuel Stabilizer . . . . . . . . . . . . . . . . . .
Fuel Tank Filler Cap . . . . . . . . . . . . .
M
90
65
70
74
31
21
89
31
G
Gap, Spark Plug . . . . . . . . . . . . . . . .
Gasoline Handling . . . . . . . . . . . . . .
Gear Selector. . . . . . . . . . . . . . . . . . .
Gearcase Oil, Main . . . . . . . . . . . . . .
Gearcases
Main Gearcase . . . . . . . . . . . . . . .
Transmission . . . . . . . . . . . . . . . .
Gears, shifting . . . . . . . . . . . . . . . . . .
Gloves . . . . . . . . . . . . . . . . . . . . . . . .
65
21
33
61
61
61
33
11
H
Hand Hold, Passenger. . . . . . . . . . . . 27
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 10
32
72
38
29
74
69
82
77
52
K
Key, Periodic Maintenance Chart . . . 54
L
Lamp Replacement
Taillight . . . . . . . . . . . . . . . . . . . .
Daytime Running Lights . . . . . . .
Lights . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant Part Numbers . . . . . . . . . .
Lubrication for Storage . . . . . . . . . . .
Lubrication Recommendations . . . . .
N
Nets, Cab. . . . . . . . . . . . . . . . . . . . . . 30
New Operator Procedures. . . . . . 42-43
Noise Emission Control System . . . . 52
O
Obstacles. . . . . . . . . . . . . . . . . . . . . . 49
Oil
Engine . . . . . . . . . . . . . . . . . . 59-60
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . . 61
Oil Change
Engine Oil . . . . . . . . . . . . . . . . . . 60
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . . 61
Oil Check
Engine Oil . . . . . . . . . . . . . . . . . . 59
Main Gearcase . . . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . . 61
Operation on Public Lands . . . . . . . . 52
P
I
Ignition Switch . . . . . . . . . . . . . . . . .
Inspection, Brakes. . . . . . . . . . . . . . .
Inspection, Pre-Ride . . . . . . . . . . . . .
Inspection, Seat Belts . . . . . . . . . . . .
Inspection, Steering Wheel . . . . . . . .
Inspection, Throttle Freeplay . . . . . .
Installation, Battery. . . . . . . . . . . . . .
Installation, Wheels . . . . . . . . . . . . .
Interference, Electromagnetic . . . . . .
Maintenance Log . . . . . . . . . . 106-107
Maintenance, Periodic . . . . . . . . 53-57
78
78
78
94
90
58
Parking Brake Adjustment . . . . . . . . 64
Parking Brake Cable Freeplay . . . . . 64
Parking on an Incline . . . . . . . . . . . . 51
Parking the Vehicle. . . . . . . . . . . . . . 41
Passenger Hand Hold Adjustment . . 27
Periodic Maintenance Chart . . . . 53-57
Plug Condition . . . . . . . . . . . . . . . . . 65
Plug Gap . . . . . . . . . . . . . . . . . . . . . . 65
Plug Torque . . . . . . . . . . . . . . . . . . . 65
Plug, Spark . . . . . . . . . . . . . . . . . . . . 65
Plugs, Fouled . . . . . . . . . . . . . . . . . . 65
Polaris Products . . . . . . . . . . . . . . . . 94
Polishing the Vehicle . . . . . . . . . . . . 87
Pre-Ride Inspection . . . . . . . . . . . . . 38
Public Lands . . . . . . . . . . . . . . . . . . . 52
R
Refueling Safety . . . . . . . . . . . . . . . . 21
Registration, Warranty . . . . . . . . . . . 99
Removal, Battery . . . . . . . . . . . . . . . 81
Removal, Seat . . . . . . . . . . . . . . . . . . 26
Removal, Wheels . . . . . . . . . . . . . . . 76
Removing the Vehicle from Storage 91
Reverse . . . . . . . . . . . . . . . . . . . . . . . 50
Riding Gear. . . . . . . . . . . . . . . . . 10-11
109
INDEX
S
T
Safe Operation Practices . . . . . . . . . 39
Safety Labels . . . . . . . . . . . . . . . . 22-23
Safety Symbols . . . . . . . . . . . . . . . . . 6
Safety Warnings. . . . . . . . . . . . . . 12-21
Seat Adjustment, Driver’s . . . . . . . . 26
Seat Belt Cleaning . . . . . . . . . . . . . . 29
Seat Belt Inspection . . . . . . . . . . . . . 29
Seat Belts . . . . . . . . . . . . . . . . . . . 28-29
Seat Removal . . . . . . . . . . . . . . . . . . 26
Selector, Gear . . . . . . . . . . . . . . . . . 33
Severe Use Definition . . . . . . . . . . . 53
Shifting Gears . . . . . . . . . . . . . . . . . 33
Shock Spring Adjustment . . . . . . . . 74
Signal Words . . . . . . . . . . . . . . . . . . . 6
Spark Arrester Cleaning . . . . . . . . . 68
Spark Arrester Warning. . . . . . . . . . 68
Spark Plug . . . . . . . . . . . . . . . . . . . . 65
Spark Plug Condition. . . . . . . . . . . . 65
Spark Plug Gap . . . . . . . . . . . . . . . . 65
Spark Plug Removal . . . . . . . . . . . . 65
Spark Plug Torque . . . . . . . . . . . . . . 65
Spark Plugs, Fouled . . . . . . . . . . . . . 65
Specifications. . . . . . . . . . . . . . . . 92-93
Speed Control System . . . . . . . . . . . 35
Stabilizing the Fuel . . . . . . . . . . . . . 89
Steering Wheel Adjustment. . . . . . . 27
Steering Wheel Inspection. . . . . . . . 74
Stopping the Engine. . . . . . . . . . . . . 41
Storage . . . . . . . . . . . . . . . . . . . . . 86-91
Storage and Inspection. . . . . . . . . . . 90
Storage and Lubrication. . . . . . . . . . 90
Storage Area . . . . . . . . . . . . . . . . . . 90
Storage, Battery . . . . . . . . . . . . . . . . 83
Storage, Covers . . . . . . . . . . . . . . . . 90
Storage, Fluid Levels . . . . . . . . . . . . 89
Storage, Oil Change. . . . . . . . . . . . . 89
Storage, Removal. . . . . . . . . . . . . . . 91
Taillight . . . . . . . . . . . . . . . . . . . . . . . 78
Throttle Freeplay Adjustment . . . . . . 70
Throttle Freeplay Inspection . . . . . . . 69
Throttle Freeplay, Freeplay, Throttle 69
Throttle Pedal . . . . . . . . . . . . . . . . . . 34
Throttle System . . . . . . . . . . . . . . . . . 69
Tire Tread Depth . . . . . . . . . . . . . . . . 76
Tires . . . . . . . . . . . . . . . . . . . . . . 76-77
Front Wheel Hub Tightening . . . . 76
Wheel Nut Torque . . . . . . . . . . . . 77
Toe Alignment. . . . . . . . . . . . . . . . . . 75
Torque, Spark Plug . . . . . . . . . . . . . . 65
Transmission Oil . . . . . . . . . . . . . . . . 61
Transporting the Vehicle . . . . . . . . . . 91
Tread Depth, Tire . . . . . . . . . . . . . . . 76
110
V
Vehicle Identification Numbers. . . . . . 8
Vehicle Immersion . . . . . . . . . . . . . . 79
Vehicle Transport . . . . . . . . . . . . . . . 91
W
Warning Symbols . . . . . . . . . . . . . . . . 6
Washing the Vehicle . . . . . . . . . . 86-87
Water, Immersion of Vehicle . . . . . . 79
Wear, Drive Belt . . . . . . . . . . . . . . . . 95
Wheel Hub Tightening . . . . . . . . . . . 76
Wheel Installation . . . . . . . . . . . . . . . 77
Wheel Nut Torque Specifications . . . 77
Wheel Removal . . . . . . . . . . . . . . . . . 76
PMS 419
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER allow vehicle to be operated:
• without all occupants first viewing and understanding safety video
and warning labels.
• with more than one passenger.
• on hills steeper than 15 degrees
15 .
• on paved surfaces - pavement may seriously affect handling and control.
• with non-Polaris approved accessories - they may seriously affect stability.
• at speeds that are too fast for the operator’s skills, the conditions
and/or the terrain.
ALWAYS require operator and passenger to:
• wear seat belts, grab hand holds (passenger) and plant feet firmly on the floor.
• secure cab nets.
• keep hands and feet inside vehicle.
• avoid quick turns of the steering wheel and driving stunts such as jumps,
donuts or power slides.
• reduce speed and use extra caution when carrying a passenger.
• watch for branches or other hazards that could enter vehicle.
Operation of this vehicle by children under age 10 increases the risk of severe
injury or death. Adult supervision required for children under age 16.
NEVER permit children under age 10 to operate or ride in this vehicle.
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
FOR ALL OCCUPANTS.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer,
call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9926400 Rev 02
Printed in Taiwan
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