Polaris Sportsman 800 Touring Quadricycle Owner's Manual

Pantone 425 C

GB D E F

I

FI P S PASSENGER UNDER 12 Before you operate or ride this vehicle, read the owner’s manual.

Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren.

Antes de operar o conducir este vehículo, lea el Manual del propietario.

Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule.

Prima di usare o guidare il veícolo, leggere il Manuale di istruzioni.

Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.

Antes de utilizar ou andar neste veículo, leia o Manual do proprietário.

Innan du hanterar eller kör detta fordon, läs Handboken.

For your nearest Polaris dealer, visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A.

Part No. 9921454 Rev 03 Printed in U.S.A.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles •

RANGER

utility vehicles • Victory motorcycles Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about Polaris, visit us online at www.polarisindustries.com.

1

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc.

Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

2008 Sportsman 800 Touring Quadricycle Owner’s Manual P/N 9921454 2

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . . . . . 64 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118 Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3

4

KNOW YOUR VEHICLE

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protec tion of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly.

Know all laws and regulations concerning the opera tion of this vehicle in your area.

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Engine Serial Number VIN #### Key Number Vehicle Model Number: ___________________________________________________ Frame VIN: _____________________________________________________________ Engine Serial Number: ____________________________________________________ Key Number: ___________________________________________________________ 5

6

SAFETY

Rider Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym bols are used.

Become familiar with their meanings before reading the manual.

The

safety alert symbol

, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The

safety alert warning

indicates a potential hazard that may result in serious injury or death.

CAUTION

The

safety alert caution

indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A

caution

indicates a situation that may result in damage to the vehicle.

NOTE

A

note

will alert you to important information or instructions.

SAFETY

Rider Safety WARNING

Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating a Polaris Quadricycle.

Safety Training

When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this informa tion on a regular basis. If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road.

Equipment Modifications

The warranty on your Polaris Quadricycle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

NOTE:

The addition of certain accessories, including (but not limited to) mow ers, blades, tires, sprayers and large racks may change vehicle han dling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

7

8

SAFETY

Rider Safety WARNING

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle.

Never operate a Quadricycle without proper instruction.

Take a training course.

Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle.

Never carry more than one passenger on this 2-up Quadricycle.

Rider Safety

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating a Quadricycle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Never attempt jumps or other stunts.

SAFETY

9

SAFETY

Rider Safety

Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 43.

Keep both hands on the handlebars. Keep both feet on the footrests.

A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

Always follow the procedures outlined in this manual for turning. See page 47.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

10

SAFETY

Rider Safety

If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Always follow the procedures outlined in this manual for driving on hills. See page 50. Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15 ° .

Never operate with the differential unlocked ( ) while operating on a to ADC 4X4 before ascending or descending a hill.

>15 ° hill or other irregular terrain. See pages 23 and 31. Always move the 4X4 switch Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 53.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 52.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

11

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 54.

Always follow the procedures outlined in this manual for operating over obstacles. See page 59.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 58.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 56.

12

Rider Safety

Always follow the procedures outlined in this manual for driving in reverse. See page 61.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

SAFETY

13

SAFETY

Rider Safety

Never operate the Quadricycle on a frozen body of water.

Operating on paved surfaces may affect the handling and control of the Quadricycle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 27.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about Quadricycle safety, contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

14

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

The following pages repeat the information found on each decal.

General Alert (Multi-Lingual)

Before you operate or ride this vehicle, read the owner’s manual.

+ General Alert

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 15 degrees and brakes gradually.

15 ° . • To prevent flip-over on hilly terrain, when going up or down, use throttle Age 16 Alert + + Hill Operation Alert 15

SAFETY


Front Rack Warning Reverse Override Alert + + Clutch Cover Alert + + + Rear Rack Warning Tire Pressure/ Load Alert

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY

ACCESSORIES.

568 LBS. (258 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND Read Owner's Manual for more detailed loading information.

Reverse Override Alert

Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in 4X4 (AWD). See Owner's Manual.

16

SAFETY


Rack Warning, Front and Rear

WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

Clutch Cover Alert

NO STEP 17

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet Eye Protection Long Sleeves Gloves Long Pants Boots

Helmet

Always wear a helmet that meets or exceeds established safety stan dards.

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 of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

E 4 051039 0006.31

18

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

19

FEATURES AND CONTROLS

Switches

Mode/Reverse Override Switch Differential Switch Engine Stop Switch Hazard Switch Headlight Switch Horn Switch Turn Signal Switch 4X4 Switch Main Key Switch

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 32.

To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

NOTE:

The override switch also allows activation of 4X4 in reverse, if the 4X4 switch is on.

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

20


Switches

Main Key Switch

End all electrical power to the vehicle.

LIGHTS ON

position turns the headlights on.

Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the

POSITION LIGHTS ON

position.

Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

Engine Stop Switch OFF RUN

Light Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam Low Beam Light Switch 21


Switches

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30.

4X4 Switch

Hazard Warning Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Hazard Warning Switch Differential Switch

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal.

Horn Switch

Horn Switch

Press the horn switch to sound the horn.

Turn Indicators Turn Signal Switch 22


Switches

Differential Switch

Use the differential switch to lock and unlock the rear differential.

Locked Differential:

Operate the vehicle with the switch in the locked position in most conditions.

Unlocked Differential:

When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns. Operate with an unlocked differential only as needed to protect smooth, level surfaces from tire damage. Otherwise, move the switch to the locked position.

This feature will function only if the vehicle is in 2X4 mode

.

Operating with the differential unlocked ( ground again.

) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the DO NOT operate with the differential unlocked ( 4X4 on these types of terrain.

) when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Place the differential switch in the locked position and operate in ADC 4X4 or 23


Throttle Lever

Press the throttle lever to increase engine speed and vehicle move ment. Release the lever to reduce engine speed and vehicle move ment.

WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate a Quadricycle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Quadricycle.

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

Electronic Throttle Control The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

24


Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Foot Brake

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

WARNING

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

25


Parking Brake

Locking the Parking Brake

1. Place the transmission in PARK.

2. Squeeze the brake lever toward the handlebar.

3. Push the parking brake lock forward to engage the lock. Release the brake lever.

4. To release the parking brake lock, squeeze and release the brake lever.

WARNING

Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

26


Steering Lock

Lock the steering to prevent unau thorized use or theft of the vehicle.

1. Turn the handlebars to the full right position.

NOTE:

The handlebars may also be locked in the full left position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key.

NOTE:

Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost.

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

27


Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso line with a minimum pump octane of 87.

Do not use E-85 fuel.

Fuel Tank Cap

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

28


Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

Gear Selector Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage. Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.

Passenger Seat

Latch Always make sure the passenger seat is installed and securely latched before operating with a passenger. Test the seat latch by attempting to pull the seat upward.

NOTE:

If the latch is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service.

To remove the seat, pull the latch loop at the rear of the seat. Pull the seat upward to remove it from the vehicle.

To reinstall the seat, make sure the rubber feet at the base of the seat are positioned in the rear rack. Press down firmly on the seat pad until the latch clicks 29


All Wheel Drive (4X4) System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

See page 31.

4X4

When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.

NOTE:

The override switch allows activation of 4X4 in reverse if the 4X4 switch is on. See page 20.

2X4

When the switch is on 2X4, the vehicle is in two-wheel drive at all times.

30

Engaging 4X4 FEATURES AND CONTROLS

All Wheel Drive (4X4) System

The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage 4X4 before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when

all four

of the follow ing conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 24 km/h or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if

at least one

of the fol lowing conditions occur: • The 4X4 switch is moved out of the ADC 4X4 position • Vehicle speed exceeds 24 km/h • The throttle is open (throttle is applied) • The transmission is shifted to neutral or park 31


Instrument Cluster

The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.

Speedometer Needle Speedometer Rider Information Center

NOTE:

In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.

High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

32

3.

4.

5.

6.


Instrument Cluster Rider Information Center

The rider information center is located in the instrument cluster. All seg ments will light up for 2.5 seconds at start-up.

NOTE:

If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis.

1.

Gear Indicator

shifter position: H = High Gear L = Low Gear N = Neutral P = Park - This indicator displays gear R = Reverse Gear 2 3 4 5 6 7 2.

7.

8.

4X4 Indicator

4X4.

- This indicator illuminates when the 4X4 switch is on either ADC 4X4 or

Engine Hour Display Indicator

1

Service Interval/Diagnostic Mode Indicator Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

8

Fuel Gauge

- The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

Check Engine Warning Indicator

- This indicator serves two pur poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

Mode Indicator

33



Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20.

NOTE:

The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles or kilometers traveled by the Quadricy cle.

Trip Meter Mode

The trip meter records the miles or kilometers traveled by the Quadricy cle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.

NOTE:

In the Rider Information Center, the trip meter display contains a deci mal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

NOTE:

Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page 35.

34



Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move ment of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on. Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

Clock Screen

To reset the clock: 1. Enter the diagnostic mode.

2. Toggle to the clock screen. 3. Press and hold the mode button until the hour display flashes. Release the button. 4. Press and release the mode button once to advance the setting by one hour. Press and

hold

the mode button to advance the hours quickly.

5. When the desired hour is displayed, wait approximately four sec onds, until the minute display flashes. 6. Use the same procedure to reset the minutes.

7. When the display stops flashing, the mode has been set.

NOTE: Do not turn the key switch off until the display stops flashing or the new setting will not be locked into the memory.

35



Diagnostic Mode Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). This screen is for informa tional purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 37.

NOTE:

The service interval is programmed at 50 hours at the factory.

36



Diagnostic Mode Programmable service interval

To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button. 4. Press and release the mode button once to advance the setting by one hour. Press and

hold

the mode button to advance the hours quickly.

NOTE:

If you scroll past the intended number, press and hold the button until the hours cycle back to zero.

5. When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed.

37



Diagnostic Mode Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles (MP).

3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 40 for Blink Codes and Failure Descriptions. Use the follow ing procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in PARK. Stop the engine. Turn the key switch to the ON position.

2. Turn the key switch off and on three times in less than five seconds. The word “WAIt” will appear on the screen.

38



Downloading Codes

3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.

4. Count the number of times the Check Engine icon flashes.

Example

: For the two blink codes 42 and 36, the Check Engine icon will flash 4 times, pause, then flash 2 times (code 42), then pause longer, blink 3 times, pause, and blink 6 times (code 36). 5. A code 61 will signal the end of the sequence. If no blink codes are found, only codes 12 and 61 will appear during the sequence.

NOTE:

The word “WAIt” will remain on the screen through this entire process.

Code Definitions

Open Load:

There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

The wire is shorted to ground between the electronic control unit and the item listed in the chart.

Shorted Load:

The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.

Short-to-Battery:

The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage.

39



Downloading Codes Failure Description

63 63 72 73 73 74 74 61 36 37 37 41 41 42 42 44

Blink Code

12 22 22 25 31 31 36 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant Temp Low Voltage Engine Coolant Temp High Voltage Crank Position Sensor Circuit Fault Barometric Pressure/Manifold Air Pressure Sensor Low Barometric Pressure/Manifold Air Pressure Sensor High IAC Stepper Motor: Open Load IAC Stepper Motor: Short-to-Ground Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery MIL Circuit: Open Load/Short-to-Ground MIL Circuit: Shorted Load/Short-to-Battery Fuel Pump: Open Load/Short-to-Ground Fuel Pump: Shorted Load/Short-to-Battery Fan Circuit: Open Load/Short-to-Ground Fan Circuit: Shorted Load/Short-to-Battery ADC: Open Load/Short-to-Ground ADC: Shorted Load/Short-to-Battery Starter Enable: Open Load/Short-to-Ground Starter Enable: Shorted Load/Short-to-Battery Gear Sensor Signal 4X4: Open Load/Short-to-Ground 4X4: Shorted Load/Short-to-Battery Rear Differential Enable: Open Load/Short-to-Ground Rear Differential Enable: Shorted Load/Short-to-Battery END SEQUENCE 40

OPERATION

Fuel Safety WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

41

OPERATION

Break-In Period

The break-in period for your new Polaris Quadricycle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and perfor mance of your Quadricycle more than following the procedures for a proper break-in. Careful treatment of a new engine and drive compo nents will result in more efficient performance and longer life for these components.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 28.

2. Check the engine oil level. See page 70. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Drive slowly. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 43.

6. Pull only light loads.

7. Change the oil and filter at one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggres sive acceleration and high speed operation during the break-in period.

42

Pre-Ride Checklist

Item

Hand brake/lever travel Foot brake Brake fluid Passenger seat latch Front suspension Rear suspension Steering/steering lock Steering Tires Wheels/fasteners

Remarks

Ensure proper operation Ensure proper operation Ensure proper level Ensure latch is secure Inspect, lubricate if necessary Inspect, lubricate if necessary Unlock the steering; ensure free oper ation Ensure free operation Inspect condition and pressure Inspect, ensure fastener tightness Frame nuts, bolts, fasteners Fuel and oil Coolant level (if applicable) Inspect, ensure tightness Ensure proper levels Ensure proper level Coolant hoses (if applicable) Inspect for leaks Throttle Ensure proper operation Indicator lights/switches Engine stop switch Mirrors Air filter, pre-filter Air box sediment tube Headlamp Brake light/taillight Riding gear ADC Fluid

OPERATION

Ensure operation Ensure proper operation Adjust for best side/rear vision Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec tric grease when lamp is replaced Check operation, apply Polaris dielec tric grease when lamp is replaced Wear approved helmet, goggles, and protective clothing Ensure proper level 89 89 91 28 70 80 81 24 88 20 21 24 92 95

Page

84 84 84 29 69 69 27 96 18 78 43

OPERATION

Starting the Engine WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.

1. Position the vehicle on a level surface.


3. Sit on the vehicle.

NOTE:

The starter interlock will prevent the engine from starting if the trans mission is in gear and the brake is not engaged.

4. Move the engine stop switch to RUN.

NOTE:

Do not press the throttle while starting the engine.

5. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter. Activate the starter for a maxi mum of five seconds, releasing the key when the engine starts.

500 EFI ONLY:

The starter will automatically stop if engaged for longer than 5 seconds. Move the key to the OFF position and wait 10 seconds before engaging the starter again.

6. If the engine does not start, release the starter and wait five seconds. 7. Repeat steps 5 and 6 until the engine starts.

44

OPERATION

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level fre quently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained.

Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

PVT Operation When To Use Low Range and High Range

Condition

Operating at speeds less than 11 km/h Towing heavy loads Operating in rough or rugged terrain Operating at speeds greater than 11 km/h

Range to Use

Low Low Low High 45

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 18.

2. Perform the pre-ride inspection. See page 43.


4. Mount the vehicle from the left side.

5. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars.

6. Start the engine and allow it to warm up.

7. Apply the brakes.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the brakes.

11. Slowly squeeze the throttle lever toward the handlebar to begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

46

OPERATION

Turning the Vehicle

1. Before turning, activate a turn sig nal to alert others of your inten tions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while support ing your weight on the outer foot rest. Use the same leaning technique for turning in reverse.

3. Never turn quickly when carrying a passenger or cargo.

4. Practice making turns at slow speeds before attempting to turn at faster speeds.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

47

OPERATION

Driving with a Passenger

Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle.

Never carry more than one passenger on this 2-up Quadricycle.

1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 18.

3. Perform the pre-ride inspection. See page 43. 4. Always make sure the passenger seat is installed and securely latched before operating with a passenger.


48

OPERATION

Driving with a Passenger

6. Mount the vehicle from the left side.

7. After the operator is seated, the passenger should mount the vehicle from the left side.

NOTE:

Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab han dles at all times. The passenger should never hold on to the operator.

8. Drive slowly. Control may be more difficult with a passenger on board. Allow more time and distance for braking.

9. Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle.

10. Do not cross a hillside with a passenger on board. See page 52.

11. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

12. Make sure the passenger understands the importance of "active riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

49

OPERATION

Driving Uphill

15 ° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

2. Avoid steep hills (15 ° maximum).

3. Avoid hills with slippery or loose surfaces.

4. Keep both feet on the footrests.

5. Shift body weight uphill.

6. Drive straight uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

50

OPERATION

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

3. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

4. Use the K-turn to turn around. See page 54.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15 ° . >15 ° Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

51

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down.

2. If operating in 2X4 mode, make sure the differential is locked ( ).

3. Avoid hills with slippery or loose surfaces.

4. Avoid crossing the sides of steep hills.

5. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside.

6. Shift your weight uphill. 7. Keep your feet on the footrests.

8. Steer slightly into the hill.

NOTE:

If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side

immediately

!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

52

OPERATION

Driving Downhill

When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down.

4. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.

5. Shift your weight rearward.

15 ° Maximum 6. Apply the brakes

slightly

to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

53

OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

2.4 m 1. Stop the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake. 8. Slowly release the brake lever and allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

54

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill.

NOTE:

A passenger should not remount until the vehicle returns to level ground.

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake. 14. Release the foot brake and drive ground.

slowly

downhill. Control speed with either the hand or foot brake until the vehicle is on level Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15 ° . >15 ° Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

55

OPERATION

Driving Through Water

Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

5. Wet brakes may have reduced stopping ability. Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal.

56

OPERATION

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

57

OPERATION

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces.

2. Engage 4X4 before wheels begin to lose traction.

3. Be alert. 4. Watch the trail. 5. Avoid quick, sharp turns.

6. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

7. Never apply the brakes during a skid.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning. Engage 4X4 when the wheels have traction.

58

Driving Over Obstacles

OPERATION

1. Always check for obstacles before operating in a new area.

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches.

5. Always have a passenger dismount before operating over an obsta cle.

Always follow the procedures outlined in this manual for operating over obstacles.

59

OPERATION

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precau tions: 1. Stop the engine.


3. Always block the rear wheels on the downhill side.

60

Driving in Reverse

OPERATION

Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view.

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes

lightly

for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

61

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.

• Read and understand the load distribution warnings listed on the vehicle warning labels.

• Never exceed the stated load capacity for this vehicle.

• Never carry cargo on the rear rack when operating the ATV in the 2-up mode with a passenger.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. Reduce load weight when cargo is high. Secure off centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn. Split the load between the front rack and rear rack, with 1/3 in the front and 2/3 in the back. Do not exceed load capacities. See specifications beginning on page 118.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

• USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

62

Hauling Cargo

2/3 1/3 OPERATION

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15 ° .

Maximum Towing Capacities

Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 680 kg 68 kg Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 17 cm. Never install automotive accessories on your Polaris Quadricycle. Always install Polaris-approved (or equivalent) accessories designed for Quadricycle use.

Maximum 17 cm 63

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian ICES-002 and European directives 89/336/EEC and 97/24/EC.

64

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 32.

Record maintenance and service in the Maintenance Log beginning on page 128.

NOTE:

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Severe Use Definition

• Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

65

MAINTENANCE

Periodic Maintenance Chart Maintenance Chart Key

X

E

Perform these operations more often for vehicles subjected to severe use.

Emission-related service Q Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Polaris dealer perform these services.

Q could result in component failure and lead to serious injury or death. Have an authorized Perform all services at whichever maintenance interval is reached first.

Item

X X

E

X Steering Front suspension Rear suspension Tires Brake fluid level Brake lever Foot brake Brake system Passenger seat latch Wheels/fasteners Frame fasteners Engine oil level Air filter, pre-filter Air box sediment tube Coolant

Maintenance Interval

(whichever comes first)

Hours Calendar Kilometers

Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride -

Remarks

Make adjustments as need ed. See Pre-Ride Checklist on page 43.

Pre-Ride Pre-Ride Pre-Ride Daily Daily Daily Inspect; clean often; replace as needed Drain deposits when visible X ADC fluid Headlight/taillight Daily Daily Check level daily, change coolant every 2 years Check level daily, add as needed Check operation; apply dielectric grease if replacing lamps 66

MAINTENANCE


Item Maintenance Interval



Weekly -

Remarks

Inspect; replace as needed X X Q

E

X X

E

X X

E

X Q Air filter, main element Brake pad wear X X X Q Battery Demand drive fluid Rear gearcase oil (if equipped) Transmission oil Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Shift linkage Steering Front suspension Rear suspension Throttle cable/ ETC switch 10 20 25 25 25 25 50 50 50 50 50 50 Monthly Monthly Monthly Monthly Monthly Monthly 1 M 3 M 6 M 6 M 6 M 6 M 6 M 160 320 400 400 400 400 800 800 800 800 800 800 Inspect periodically Check terminals; clean; test Inspect level; change yearly Inspect level; change yearly Inspect level; change yearly Inspect; clean if needed Perform a break-in oil change at one month Lubricate all fittings, pivots, cables, etc.

Inspect, lubricate, adjust Lubricate Lubricate Lubricate Inspect; adjust; lubricate; replace if necessary

E

Throttle body intake duct Drive belt Cooling system X Engine oil change X X Oil filter change Oil tank vent hose (if equipped) 50 50 50 100 100 100 6 M 6 M 6 M 6 M 6 M 6 M 800 800 1600 1600 1600 1600 Inspect duct for proper seal ing/air leaks Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at one month Replace with oil change Inspect routing, condition 67

MAINTENANCE


Q

E

Q

E

X

Item

Valve clearance Fuel system Radiator X X Q

E

X Cooling hoses Engine mounts Exhaust muffler/ pipe Spark plug Wiring

Maintenance Interval



100 12 M 1600 100 100 100 100 100 100 12 M 12 M 12 M 12 M 12 M 12 M 1600 1600 1600 1600 1600 1600

Remarks

Inspect; adjust Check for leaks at tank cap, lines, filter, pump; replace lines every 2 years Inspect; clean external surfaces Inspect for leaks Inspect Inspect Inspect; replace as needed Q Q Q Q X Q

E

Clutches (drive and driven) Front wheel bearings Brake fluid ADC fluid Fuel filter Q Spark arrestor Toe adjustment Headlight aim 100 100 100 200 200 H 200 300 12 M 12 M 12 M 24 M 24 M 24 M 36 M 1600 1600 1600 3200 3200 4800 Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts Inspect; replace as needed Change every two years 2000 (3200) Change every two years Replace every 2 years, more often under severe use Clean out Inspect periodically; adjust when parts are replaced Adjust as needed X

E

Q Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service Have an authorized Polaris dealer perform these services.

68

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Items not listed in the chart should be lubricated at the General Lubrication interval.

NOTE:

The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item

Engine Oil

Lube Capacity at Fluid Change

2 qt. (1.9 l)

Method

See page 70.

Brake Fluid Transmission Oil Demand Drive Fluid (Front Gearcase) ADC Fluid Front Prop Shaft Yoke PS-4 PLUS Performance Synthetic 2W-50 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Demand Drive LT Pre mium Fluid Polaris ADC Fluid Polaris Premium U-Joint Lube -- See page 82.

32 oz. (948 ml) See page 74.

9.3 oz. (275 ml) See page 76.

-- -- See page 78.

Grease fittings (3 pumps maximum) every 800 km, before long periods of stor age, or after pressure washing or submerg ing.

Front Prop Shaft Yoke 69

MAINTENANCE

Engine Oil Oil Recommendations

Always change the oil filter whenever changing oil.

Polaris recommends the use of Polaris PS-4 ture operation

PLUS Performance

Syn thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil. Never substitute or mix oil brands.

Oil Specifications

Lubricant

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

Capacity

1.9 liters

Drain Plug Torque

27 N-m 70

Engine Oil Oil Level



3. Lift the lever lock. Remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall the dipstick completely, but do not lock it.

Dipstick

MAINTENANCE

5. Remove the dipstick and check the oil level on the top side of the dipstick.

6. Maintain the oil level in the safe range. Do not overfill.

NOTE:

The oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface of the dipstick.

7. Reinstall the dipstick.

8. Secure the lever lock.

Safe Range { Check Level on Top Side Safe Add Oil 71

MAINTENANCE

Engine Oil Oil and Filter Change CAUTION

Hot oil may result in serious burns. Do not allow hot oil to contact skin.



3. Start the engine. Allow it to idle for 2-3 minutes.

4. Stop the engine.

5. Clean the area around the drain plug.

Drain Plug Location to front 6. Remove the drain plug. Drain the oil into a drain pan.

7. Clean the drain plug. Reinstall the drain plug with a new sealing washer.

8. Torque to specification. See page 70.

72

Engine Oil Oil and Filter Change

9. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

10. Clean the filter sealing area on the crankcase.

11. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.

12. Install the new oil filter. After the filter contacts the crankcase surface, turn it 1/2 turn by hand.

13. Remove the dipstick.

14. Add 1.9 liters of recommended oil.

MAINTENANCE


16. Start the engine. Allow it to idle for 1-2 minutes.

17. Stop the engine.

18. Check for leaks.

19. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

20. Discard used oil and filter properly.

Safe Range { Safe Add Oil 73

MAINTENANCE

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil.

See page 120 for the part numbers of Polaris products.

Transmission Oil Recommendations

Lubricant

Premium AGL Synthetic Gearcase Lubricant

Oil Change Capacity

948 ml

Transmission Oil Level



Fill Plug Torque

30 N-m


30 N-m 3. Remove the fill plug.

4. Check the oil level. Add the recommended oil as needed. Do not overfill.

5. Reinstall the fill plug. Torque to specification.

Oil Level 74

Transmission Oil Transmission Oil Change



3. Remove the fill plug.

4. Remove the drain plug.

5. Drain the oil into a drain pan.

6. Clean the drain plug.

7. Reinstall the drain plug. Torque to specification. See page 74.

8. Add the recommended oil. See page 74.

9. Reinstall the fill plug. Torque to specification. See page 74.

10. Check for leaks.

11. Discard used oil properly.

MAINTENANCE

75

MAINTENANCE

Front Gearcase (Demand Drive) Fluid Fluid Recommendations

Gearcase

Demand Drive Unit

Lubricant

Demand Drive LT Premium Fluid

Capacity

275 ml

Fill Plug Torque

11-14 N-m Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 120 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads.

Fill Plug Fill Level


15 N-m Drain Plug

Fluid Level



3. Remove the fill plug. Check the fluid level.

4. Add the recommended demand drive fluid as needed.


76

Fluid Change

MAINTENANCE

Front Gearcase (Demand Drive) Fluid



3. Remove the fill plug.

4. Remove the drain plug. Drain the fluid into a drain pan.

5. Clean the drain plug.

6. Reinstall the drain plug. Torque to specification. See page 76.

7. Add the recommended fluid.


9. Check for leaks.

10. Discard used oil properly.

77

MAINTENANCE

Active Descent Control (ADC) Fluid

The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 120 for the part numbers of Polaris products.

Fluid Level


2. Open the front box cover.

3. Open the access door.

4. View the fluid level in the reservoir.

5. Remove the cap and add the recommended fluid as needed.

NOTE:

DO NOT use brake fluid.

6. Maintain the fluid level between the minimum and maximum marks. Do not over fill.

ADC Fluid Reservoir 78

Fluid Change

MAINTENANCE

Active Descent Control (ADC) Fluid

1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir.

NOTE:

Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow fluid and trapped air to flow from the fitting. Close the valve when clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT:

Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 9 N-m. Reinstall the valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks. Make sure the reservoir is free of debris.

9. Reinstall the cap securely. Clean up any drips or spills.

79

MAINTENANCE

Cooling System

Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 120 for the part num bers of Polaris products.

NOTE:

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

Recovery Bottle Coolant

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Add coolant as needed.

NOTE:

Check the coolant level in the radiator any time the recovery bottle has run dry. Add coolant as needed.

1. Check the coolant level when the fluid is cool.

2. Remove the left side panel. See page 87.

NOTE:

Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

3. View the coolant level.

4. Add coolant as needed.

5. Reinstall the side panel.

80

MAINTENANCE

Cooling System Radiator Coolant WARNING

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot.



3. Remove the radiator pressure cap.

4. If coolant is not visible, slowly add coolant through the radiator filler neck.

5. Reinstall the pressure cap.

6. Secure the access door and box cover.

NOTE:

Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

81

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for ser vice.

WARNING

Operating the Quadricycle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the Quadricycle with spongy feeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 120 for the part numbers of Polaris products.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

82

Brake Fluid Hand Brake

The master cylinder is located on the left handle bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

MAINTENANCE

Master Cylinder Indicator Window 1. Position the vehicle on a level surface. Make sure the handlebars are straight.

2. View the fluid level through the indicator win dow (eye) on the top of the master cylinder.

NOTE:

The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended fluid as needed. Do not overfill.

Full Low

Foot Brake

Check the brake fluid level frequently for the foot brake system. The reservoir is located under the seat. Maintain the fluid level between the maximum and minimum marks.

83

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by apply ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

Perform the following checks to keep the brake systems in good operat ing condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 82.

2. Check the brake systems regularly for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface condition of the disc.

1 mm 84

MAINTENANCE

Toe Alignment WARNING

Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.


2. Place the handlebars in a straight-ahead position.

Stand 3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire.

String

NOTE:

If available, you may use a long straight edge instead of string.

2 4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. 1 The rear measurement should be 2-3 mm more than the front mea surement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

NOTE:

If you discover improper alignment, see your Polaris dealer for service.

85

MAINTENANCE

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height.

NOTE:

Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the front two bolts to 14-17 N-m, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear of the clamp blocks.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.

14-17 N-m

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Adjuster 86

Side Panel Removal

1. Remove the seat.

MAINTENANCE

2. Grasp the rear of the side panel near the rear cab.

3. With a firm motion, pull the panel outward to disengage the side panel from the grommet.

4. Pull the panel downward and rearward to remove it.

5. When reinstalling side panels, align the fasteners and press firmly to secure them.

Footwell Removal

1. Remove the six screws on the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

Rivets Screws 87

MAINTENANCE

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable adjuster at the handlebar.

2. Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster.

Boot 3. Loosen the adjuster lock nut.

Lock Nut Adjuster 4. Rotate the boot to turn the adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever.

NOTE:

Move the throttle lever back and forth while adjusting.

1.6-3.2 mm 5. Tighten the lock nut.

6. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

NOTE:

Engine RPM should not increase when steering is turned full left or right. Readjust cable freeplay if this occurs.

88

MAINTENANCE

Tires

Refer to the specifications section beginning on page 118 for recom mended tire type, size and pressure.

WARNING

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.

• Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner's manual.

• Use only original equipment size and type when replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

3 mm

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com ponent operations. All service must be performed by your authorized Polaris dealer.

89

MAINTENANCE

Tires Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos ened for maintenance service.

Cast Aluminum

122 Nm

Nut Type

Lug Nut 2-Piece Flange Nut 37 Nm

Steel Nut Torque

122 Nm 37 Nm 90

MAINTENANCE

Tires

Always use original equipment size and type when replacing tires. Install wheels properly.

Wheel Removal/Installation



3. Loosen the wheel nuts slightly.

4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger tight.

9. Lower the vehicle to the ground.

10. Torque the wheel nuts to specification. See torque chart on page 90.

91

MAINTENANCE

Air Filter

Always clean and replace the air and breather filters at the intervals out lined in the Periodic Maintenance Chart beginning on page 65.



3. Remove the seat.

4. Release the air box cover clips.

5. Remove the air box cover.

6. Loosen the hose clamp.

7. Remove the filter.

8. Remove the pre-filter from the filter.

Pre-Filter Main Filter 9. Wash the pre-filter in soapy water. Rinse and air dry.

NOTE:

Replace the filter if needed.

10. Reverse the steps to reinstall all components.

92

MAINTENANCE

Breather Filter/Hose

The breather filter is on the hose between the engine and air box.

1. Remove the left side panel. See page 87.

2. Remove the hose clamps from the filter and pull the filter out of the hoses.

3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter.

Breather Filter 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall the filter and hose clamps.

NOTE:

The filter is effective with the arrow pointing in either direction.

Operation of your vehicle without a breather filter can cause engine damage.

93

MAINTENANCE

Lights High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall.


3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

7.6 m

X X

5 cm

NOTE:

Include rider weight on the seat when measuring.

4. Start the engine.Turn the head light switch to high beam.

Screw 5. Observe the headlight aim on the wall. The most intense part of the headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right.

94

MAINTENANCE

Lights WARNING

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp.


2. Open the front rack cover.

3. Remove the plug at the back of the headlight.

4. Pull the harness plug to disconnect it from the back of the headlight.

5.

Position light: Headlamp:

Rotate the socket to remove it. Go to step 6.

Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counter clockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the headlight.

Position Light Collar Socket Headlamp 95

MAINTENANCE

Lights Taillight Lamp Replacement


2. Rotate the taillight socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

Front Turn Signal Lamp Replacement


2. Remove the lens attachment screw.

3. Rotate the lamp to remove it.

Screw 4. Install the new lamp.

5. Reinstall the lens.

Lamp

Rear Turn Signal Lamp Replacement


2. Rotate the turn signal socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

96

MAINTENANCE

Fuse Replacement

If the engine stops or will not start, or if you experience other electrical fail ures, a fuse may need replacement.

NOTE:

Spare fuses are provided in a compartment on the top of the access door.



3. Remove the suspect fuse from the fuse panel. Install a new fuse with the same amperage.

4. Secure the access door.

5. Secure the box cover.

Fuses

5

or

6 15 20 20

Fuse Panel 97

MAINTENANCE

Spark Plugs Spark Plug Recommendations

Refer to the specifications section beginning on page 118 for the recom mended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition

New Spark Plug Previously Installed Spark Plug

Torque Specification

12-15 N-m 23-27 N-m

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

Normal Spark Plug

The normal insulator tip is tan or brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE:

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil con sumption, use of non-recommended oil or incorrect throttle body adjust ments.

98

MAINTENANCE

Spark Plugs Spark Plug Removal

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

1. Remove the spark plug cap.

2. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it.

3. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation.

4. Reinstall the spark plug. Torque to specification. See page 98.

5. Reinstall the spark plug cap.

99

MAINTENANCE

Vehicle Immersion

If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro cedure.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

1. Move the vehicle out of the water.

2. Remove the spark plug.

3. Drain any water found in the air box.

100

Vehicle Immersion

4. Turn the ignition key past the POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds.

5. Dry the spark plug. Reinstall the plug or install a new plug.

6. Torque to specification. See page 98.

MAINTENANCE

7. Attempt to start the engine. If necessary, repeat the drying procedure.

8. Have the vehicle serviced by your dealer promptly, whether you succeed in starting it or not.

NOTE:

If water has been ingested into the PVT, follow the procedure on page 105 for drying out the PVT.

101

MAINTENANCE

Spark Arrestor

Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor.

WARNING

Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it's inclined. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.



3. Remove the arrestor clean-out plug from the bottom of the muffler.

4. Start the engine.

5. Quickly squeeze and release the throttle lever several times to purge car bon from the system.

102

Spark Arrestor

6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves.

7. Lightly tap on the exhaust pipe with a rubber mallet while repeat ing step 5.

MAINTENANCE

8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. Block the wheels. 9. Place the transmission in PARK. Repeat steps 5 to 7 until no more particles are expelled.

30 cm 10. Stop the engine. Allow the arrestor to cool.

11. Reinstall the arrestor plug and remove the exhaust outlet cover or plug.

103

MAINTENANCE

PVT System

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

104

MAINTENANCE

PVT System PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating.

1. Position the vehicle on a level surface. 2. Place the transmission in PARK.

3. Remove the drain plug. Allow the water to drain completely. Rein stall the drain plug. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE:

Do not hold the throttle wide open for more than 10 seconds.

6. Allow the engine RPM to settle to idle speed, then shift the trans mission to the lowest available range.

7. Test for belt slippage. If the belt slips, repeat the process.

8. Take the vehicle to your dealer for service as soon as possible.

105

MAINTENANCE

Battery

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the termi nals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote:

External

: Flush with water.

Internal Eyes

: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

: 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.

106

MAINTENANCE

Battery WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery Removal


2. Disconnect the battery hold-down strap.

3. Remove the battery cover (if equipped).

4. On conventional batteries, remove the battery vent tube.

5. Disconnect the black (negative) battery cable first.

6. Disconnect the red (positive) battery cable last.

7. Lift the battery out of the vehicle. Be careful not to tip a conven tional battery sideways, which could spill electrolyte.

NOTE:

If electrolyte spills, immediately wash it off with a solution of one table spoon baking soda and one cup water to prevent damage to the vehi cle.

107

MAINTENANCE

Battery Battery Installation

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat teries do not have a vent tube).

NOTE:

The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent con tact with electrolyte.

WARNING

Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Install the battery cover (if equipped).

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed.

NOTE:

Cables should be safely tucked away at the front and rear of the bat tery.

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE:

Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 120 for the part numbers of Polaris products.

108

MAINTENANCE

Battery Battery Fluid (Conventional Battery)

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

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging. See page 107.

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 grav ity to 1.270 or greater.

3. Reinstall the battery. See page 108. 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 installa tion 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.

109

MAINTENANCE

Battery Battery Charging (Sealed Battery)

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

NOTE:

When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

WARNING

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

NOTE:

Always verify battery condition before and 1-2 hours after the end of charging.

State of Charge

100% 75%-100% 50%-75% 25%-50% 0%-25%

Voltage

12.8-13.0 volts 12.5-12.8 volts 12.0-12.5 volts 11.5-12.0 volts 11.5 volts or less

Action

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 Needs charge with desulfating charger

Charge Time

(Using constant current charger @ standard amps specified on top of battery) None required 3-6 hours 5-11 hours At least 13 hours, verify state of charge At least 20 hours 110

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. 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.

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.

111

MAINTENANCE

Cleaning and Storage Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow ing items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Labels and decals • Electrical components and wiring

NOTE:

If warning and safety labels are damaged, contact your Polaris dealer for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

112

MAINTENANCE

Cleaning and Storage Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre serve wheel life and ensure a "like new" appearance for many years.

NOTE:

Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion. 3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol ished 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 out lined above.

113

MAINTENANCE

Cleaning and Storage Storage Tips

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 111.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.

NOTE:

Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust sys tems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 72.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter. See page 92.

2. Clean the air box.

3. Clean or replace the breather filter. See page 93.

4. Drain the sediment tube.

114

MAINTENANCE


Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65.

• Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. See page 114.

2. Remove the spark plug. Pour 30-45 ml of engine oil into the plug holes.

3. Reinstall the spark plug. Torque to specification. 4. Apply dielectric grease to the inside of each spark plug cap. Rein stall the caps. 5. Turn the engine over several times tive film of fresh oil.

.

Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protec 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

115

MAINTENANCE


Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65.

Battery Storage

See pages 108-109 for storage and charging procedures.

Storage Area/Covers

1. Set the tire pressure and safely support the vehicle with the tires slightly off the ground. 2. Be sure the storage area is well ventilated. 3. 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.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso ries. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your vehicle. Always install accessories that are approved for Quadricycle use. Please see your Polaris dealer.

116

MAINTENANCE

Transporting the Vehicle

Follow these procedures when transporting the vehicle.

1. Stop the engine.


3. Secure the fuel cap, oil cap and seat.

4. Remove the key to prevent loss during transporting.

5. Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

Towing a Disabled Vehicle

If towing the vehicle is necessary, shift the transmission into neutral for better mobility and to prevent damage to the belt.

Always attach the tow rope to the frame of the Quadricycle.

117

SPECIFICATIONS

Sportsman 800 Touring Quadricycle

Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug Spark Plug Gap Lubrication System Driving System Type Front Suspension Rear Suspension 568 lbs. (258 kg) (includes operator, passen ger, cargo, accessories) 795 lbs. (361 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) 150 lbs. (68 kg) (Rear rack capacity and tongue weight not to exceed 180 lbs. (82 kg) 1500 lbs. (680.4 kg) on level ground 1995 lbs. (905 kg) 86 in. (218 cm) 48 in. (122 cm) 48 in. (122 cm) 57 in. (145 cm) 11 in. (28 cm) 82 in. (208 cm) unloaded 5.4 gal. (20.5 l) 2 qts. (1.9 l) 3.4 qts. (3.2 l) 9.3 oz. (275 ml) 32 oz. (948 ml) EH0760LE 760 cc 80mm x 76mm 500 Watts @3000 RPM 10:1 Electronic Fuel Injection Electronic Ignition Variable - ECU controlled RC7YC .035 in. (0.9 mm) Pressurized Wet Sump Automatic PVT (Polaris Variable Transmis sion) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.75" (22 cm) travel * Based on EU Directive 76/432/EC 118

SPECIFICATIONS

Transmission

Sportsman 800 Touring Quadricycle

Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi (34.5 KPa) 25x11-12 / 5 psi (34.5 KPa) All-wheel hydraulic disc All-wheel hydraulic disc Transmission park lock and hydraulic lock, all wheel 2 Hi/Lo beam on bumper (37.5 watt) 8.26 watts 26.9 watts LCD

Clutching (EBS Models)

Meters (Feet)

NOTE:

Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring 0-1800 (0-6000) 1800-3700 (6000-12000) 21-74 PN 5632117 21-70 PN 5632127 Red/Blue PN 7043372 Red PN 3234452 *EBS models require no helix/spring adjustment Helix* 66-56-33 BA500 EBS PN 3234604 119

POLARIS PRODUCTS Part Number Description

2870791 2876244 2876245 2873602 2873603 2876144 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044

Engine Lubricant

Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lubricant (.95 l) Premium AGL Synthetic Gearcase Lube (3.8 l) Active Descent Control (ADC) Fluid Premium ATV Angle Drive Fluid (237 ml) Premium ATV Angle Drive Fluid (9.5 l) Pump for Gallon (3.8 l) Jug Demand Drive LT Premium Fluid (237 ml)

Coolant

60/40 Coolant (3.8 l) 60/40 Coolant (.95 l)

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season Premium All Season Grease (89 ml cartridge) Premium All Season Grease (414 ml cartridge) Starter Drive Grease Premium U-Joint Lube (89 ml) Premium U-Joint Lube (414 ml) Dielectric Grease (Nyogel TM ) Chain Lube, Aerosol (185 ml) Chain Lube, Aerosol (473 ml)

Additives / Miscellaneous

Carbon Clean Plus Fuel Stabilizer DOT4 Brake Fluid Loctite TM 565 Thread Sealant Polaris Battery Tender TM Charger 120

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (5-11 kmh) Insufficient warm-up at low ambient tempera tures Slow/easy clutch engage ment Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow Climbing over large objects from a stopped position Use low range.

Use low range or turn around using the K-turn (see page 54).

Drive at a higher speed or use low range more frequently.

Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flex ible and prevent belt burning.

Use the throttle quickly and effectively.

Use low range only.

Use low range only.

Shift the transmission to low range. Carefully use fast, aggressive throttle application to engage clutch.

WARNING

: Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Dry out the PVT. See page 105. Inspect clutch seals for damage if repeated leaking occurs.

See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.

Slippage from failure to warm up belt Wrong or missing belt Improper break-in Always warm up the belt by operating below 48 km/h for 1.6 km. Operate 8 km or more when temperature is below freezing.

Install the recommended belt.

Always break in a new belt and/or clutch. See page 42.

121

TROUBLESHOOTING

Engine Does Not Rotate

Possible Cause

Low battery voltage Loose battery connections Loose solenoid connections

Engine Backfires

Possible Cause

Weak spark from spark plug Incorrect spark plug gap or heat range Old or non-recommended fuel Loose ignition connections Water present in fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure

Solution

Recharge the battery to 12.8 VDC Check all connections and tighten Check all connections and tighten

Engine Rotates, Fails to Start

Possible Cause

Out of fuel Clogged fuel filter Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) No spark to spark plug Water or fuel in crankcase Low battery voltage Mechanical failure

Solution

Refuel Replace the filter Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer

Solution

Inspect, clean and/or replace spark plug(s) Set gap to specs or replace plugs Check all connections and tighten Replace with fresh recommended fuel See your dealer See your dealer See your dealer 122

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 See your dealer Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent line Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure

Possible Lean Fuel Cause

Low or contaminated fuel Low octane fuel Clogged fuel filter Kinked or plugged fuel vent line

Possible Rich Fuel Cause

Fuel is very high octane Stopping/starting without adequate warm-up Incorrect fuel Clogged air filter

Solution

Inspect, clean and/or replace spark plug(s) See your dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC Inspect and replace Replace with recommended fuel Inspect and clean or replace See your dealer See your dealer See your dealer

Solution

Add or change fuel, clean the fuel system Replace with recommended fuel Replace filter Inspect and replace (if equipped)

Solution

Replace with lower octane fuel Allow engine to warm up before operat ing and/or stopping Replace with recommended fuel Inspect and clean or replace 123

TROUBLESHOOTING

Engine Stops or Loses Power

Out of fuel

Possible Cause

Kinked or plugged fuel vent line Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine

Solution

Refuel, cycle key to ON position three times for 5 seconds each, then start Inspect and replace (if equipped) Replace with fresh recommended fuel Replace with fresh recommended fuel Inspect, clean and/or replace spark plug(s) See your dealer Set gap to specs or replace plug Check all connections and tighten Recharge the battery to 12.8 VDC Inspect and clean or replace See your dealer See your dealer See your dealer Clean radiator screen and core, clean engine exterior, see your dealer

Engine Overheating

Possible Cause

Debris lodged in screen Plugged Radiator

Solution

Remove and clean the screen. Pull on the top portion of the screen, then remove the lower portion.

Use a garden hose to flush any debris from the radiator fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency.

124

WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the "customer copy", please contact your dealer immediately. NO WAR RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trou ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

125

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any Quadricycle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any dam ages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond Polaris' control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the Quadricycle. The exclusive remedy for breach of this war ranty shall be, at Polaris' exclusive option, repair or replacement of any defective materi als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi tations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

126

WARRANTY

HOW TO OBTAIN WARRANTY SERVICE

If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

127

MAINTENANCE LOG

Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser vices performed.

DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

128

MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

129

INDEX Numerics

4X4 System . . . . . . . . . . . . . . . . . 30-31

A

Accessories . . . . . . . . . . . . . . . . . . 116 Active Descent Control Fluid . . . 78-79 Active Descent Control System. . . . 31 ADC System . . . . . . . . . . . . . . . . . . 31 Age Restrictions. . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . . 92 All Wheel Drive Switch. . . . . . . . . . 22 All Wheel Drive System . . . . . . . 30-31

B Battery . . . . . . . . . . . . . . . . . . 106-110

Charging (Conventional) . . . . 109 Charging (Sealed) . . . . . . 109-110 Fluid (Conventional) . . . . . . . 109 Installation . . . . . . . . . . . . . . . 108 Removal. . . . . . . . . . . . . . . . . 107 Storage . . . . . . . . . . . . . . . . . . 108 Boots . . . . . . . . . . . . . . . . . . . . . . . . 19 Brake Fluid . . . . . . . . . . . . . . . . . 82-83 Brake Inspections. . . . . . . . . . . . . . . 84 Brake, Foot . . . . . . . . . . . . . . . . . . . 25 Brake, Hand . . . . . . . . . . . . . . . . . . . 25 Brake, Parking . . . . . . . . . . . . . . . . . 26 Brakes . . . . . . . . . . . . . . . . . . . . . . . 84 Break-In Period . . . . . . . . . . . . . . . . 42 Breather Filter . . . . . . . . . . . . . . . . . 93 Breather Hose . . . . . . . . . . . . . . . . . 93

C

Cargo . . . . . . . . . . . . . . . . . . . . . . . . 63 Cargo Loading . . . . . . . . . . . . . . . . . 62 Chrome Wheel Care . . . . . . . . . . . 113 Cleaning and Storage. . . . . . . . 111-116 Clock, Setting Time . . . . . . . . . . . . . 35 Clothing . . . . . . . . . . . . . . . . . . . . . . 19 Clutching (800 EFI). . . . . . . . . . . . 119 Cold Weather Operation . . . . . . . . . 45 Coolant Bottle . . . . . . . . . . . . . . . . . 80 Coolant, Radiator. . . . . . . . . . . . . . . 81 Cooling System . . . . . . . . . . . . . . 80-81 Corrosion Removal, Chrome . . . . . 113

D

Demand Drive Fluid . . . . . . . . . . 76-77 Differential Switch . . . . . . . . . . . . . . 23 Disengaging Active Descent Control 31 Drive Belt Wear/Burn . . . . . . . . . . . 121 Drivetrain Break-In . . . . . . . . . . . . . . 42 Driving Downhill. . . . . . . . . . . . . . . . 53 Driving in Reverse. . . . . . . . . . . . . . . 61 Driving on a Sidehill . . . . . . . . . . . . . 52 Driving on Slippery Surfaces . . . . . . 58 Driving Over Obstacles . . . . . . . . . . . 59 Driving Procedures . . . . . . . . . . . . . . 46 Driving Through Water . . . . . . . . 56-57 Driving Uphill . . . . . . . . . . . . . . . 50-51 Driving with a Passenger. . . . . . . 48-49

E

Electromagnetic Interference. . . . . . . 64 Electronic Throttle Control . . . . . . . . 24 Engaging 4X4 . . . . . . . . . . . . . . . . . . 31 Engaging Active Descent Control . . . 31 Engine Break-In. . . . . . . . . . . . . . . . . 42 Engine Fogging . . . . . . . . . . . . . . . . 115 Engine Oil . . . . . . . . . . . . . . . . . . 70-73 Equipment Modifications . . . . . . . . . . 7 Exhaust Emission Control System . . 64 Eye Protection . . . . . . . . . . . . . . . . . . 19

F Fluid

Active Descent Control . . . . 78-79 Brake . . . . . . . . . . . . . . . . . . 82-83 Demand Drive . . . . . . . . . . . 76-77 Engine Oil . . . . . . . . . . . . . . 70-73 Front Gearcase. . . . . . . . . . . 76-77 Transmission . . . . . . . . . . . . 74-75

Fluid Change

ADC Fluid . . . . . . . . . . . . . . . . . 79 Demand Drive . . . . . . . . . . . . . . 77 Engine Oil . . . . . . . . . . . . . . 72-73 Transmission . . . . . . . . . . . . . . . 75

Fluid Level

ADC Fluid . . . . . . . . . . . . . . . . . 78 Demand Drive . . . . . . . . . . . . . . 76 Engine Oil . . . . . . . . . . . . . . . . . 71 Transmission . . . . . . . . . . . . . . . 74 130

F Fluid Recommendations

ADC Fluid. . . . . . . . . . . . . . . . . 78 Demand Drive. . . . . . . . . . . . . . 76 Engine Oil . . . . . . . . . . . . . . . . . 70 Transmission. . . . . . . . . . . . . . . 74 Foot Brake. . . . . . . . . . . . . . . . . . . . . 25 Footwell Removal. . . . . . . . . . . . . . . 87 Front Gearcase Fluid. . . . . . . . . . 76-77 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 28 Fuel Safety . . . . . . . . . . . . . . . . . . . . 41 Fuel Tank Cap. . . . . . . . . . . . . . . . . . 28 Fuel Valve. . . . . . . . . . . . . . . . . . . . . 28 Fuse Replacement . . . . . . . . . . . . . . . 97

G

Gear Selector. . . . . . . . . . . . . . . . . . . 29 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 19

H

Handlebar Adjustment . . . . . . . . . . . 86 Hauling Cargo. . . . . . . . . . . . . . . 62-63 Hazard Warning Switch . . . . . . . . . . 22 Headlight Lamp . . . . . . . . . . . . . . . . 95 Helmet. . . . . . . . . . . . . . . . . . . . . . . . 18 High Beam Adjustment . . . . . . . . . . 94 High Range Use . . . . . . . . . . . . . . . . 45 Horn Switch . . . . . . . . . . . . . . . . . . . 22 Hub Tightening . . . . . . . . . . . . . . . . . 89

I-K

Immersion . . . . . . . . . . . . . . . . . . . . 101 Immersion Maintenance . . . . . . . . . 100 Instrument Cluster. . . . . . . . . . . . 32-40 Key Switch . . . . . . . . . . . . . . . . . . . . 21 K-Turn . . . . . . . . . . . . . . . . . . . . 54-55

Lights L

Light Switch . . . . . . . . . . . . . . . . . . . 21 Front Turn Signal . . . . . . . . . . . 96 Headlight Lamp . . . . . . . . . . . . 95 High Beam Adjustment . . . . . . 94 Position Light Lamp . . . . . . . . . 95 Rear Turn Signal. . . . . . . . . . . . 96 Taillight. . . . . . . . . . . . . . . . . . . 96 Low Range Use. . . . . . . . . . . . . . . . . 45 Lubrication Guide . . . . . . . . . . . . . . . 69

INDEX M

Maintenance Chart . . . . . . . . . . . 65-68 Mirrors . . . . . . . . . . . . . . . . . . . . . . . 24 Mode Switch. . . . . . . . . . . . . . . . . . . 20 Modifications . . . . . . . . . . . . . . . . . . . 7

N

Noise Emission Control System . . . . 64

O Oil

Engine . . . . . . . . . . . . . . . . . 70-73 Transmission. . . . . . . . . . . . 74-75

Oil Change

Engine . . . . . . . . . . . . . . . . . 72-73 Transmission. . . . . . . . . . . . . . . 75

Oil Level

Engine . . . . . . . . . . . . . . . . . . . . 71 Transmission. . . . . . . . . . . . . . . 74

Oil Recommendations

Engine Oil. . . . . . . . . . . . . . . . . 70 Transmission. . . . . . . . . . . . . . . 74 Override Switch . . . . . . . . . . . . . . . . 20

P

Parking Brake . . . . . . . . . . . . . . . . . . 26 Parking on an Incline . . . . . . . . . . . . 60 Passenger Seat . . . . . . . . . . . . . . . . . 29 Periodic Maintenance Chart . . . . 65-68 Polaris Product List. . . . . . . . . . . . . 120 Polishing the Vehicle . . . . . . . . . . . 112 Position Light Lamp . . . . . . . . . . . . . 95 Pre-Ride Checklist . . . . . . . . . . . . . . 43 PVT Break-In . . . . . . . . . . . . . . . . . . 42 PVT Operation . . . . . . . . . . . . . . . . . 45 PVT System . . . . . . . . . . . . . . 104-105

R

Reverse Operation . . . . . . . . . . . . . . 61 Reverse Override Switch . . . . . . . . . 20 Rider Information Center . . . . . . 33-40 Rider Safety . . . . . . . . . . . . . . . . . 6-14 Riding Gear. . . . . . . . . . . . . . . . . 18-19 131

INDEX S Safety Decals

Age 16 Alert . . . . . . . . . . . . . . 15 General Alert . . . . . . . . . . . . . . 15 Hill Operation Alert. . . . . . . . . 15 Rack Warning, Front and Rear 17 Reverse Override Alert . . . . . . 16 Tire Pressure/Load Alert . . . . . 16 Safety Training . . . . . . . . . . . . . . . . . 7 Service Interval Programming. . . . . 37 Severe Use . . . . . . . . . . . . . . . . . . . . 65 Side Panel Removal. . . . . . . . . . . . . 87 Sidehilling . . . . . . . . . . . . . . . . . . . . 52 Signal Words . . . . . . . . . . . . . . . . . . . 6 Spark Arrestor . . . . . . . . . . . . . 102-103 Spark Arrestor Requirements . . . . . 64 Spark Plug Inspection . . . . . . . . . . . 98 Spark Plug Recommendations. . . . . 98 Spark Plug Torque Specification . . . 98 Spark Plugs . . . . . . . . . . . . . . . . . 98-99 Specifications. . . . . . . . . . . . . . 118-119 Spring Adjustment, Rear Shock . . . 86 Starting the Engine . . . . . . . . . . . . . 44 Steering Assembly . . . . . . . . . . . . . . 86 Steering Lock. . . . . . . . . . . . . . . . . . 27 Storage . . . . . . . . . . . . . . . . . . . 111-116 Storage Tips . . . . . . . . . . . . . . . 114-116

Switches

4X4 Switch . . . . . . . . . . . . . . . 22 Differential Switch. . . . . . . . . . 23 Engine Stop Switch . . . . . . . . . 21 Hazard Warning. . . . . . . . . . . . 22 Horn . . . . . . . . . . . . . . . . . . . . . 22 Light Switch . . . . . . . . . . . . . . 21 Main Key Switch . . . . . . . . . . . 21 Mode/Reverse Override Switch 20 Turn Signal . . . . . . . . . . . . . . . 22

T

Taillight . . . . . . . . . . . . . . . . . . . . . . . 96 Throttle Cable Freeplay . . . . . . . . . . . 88 Throttle Lever . . . . . . . . . . . . . . . . . . 24 Tire Tread Depth . . . . . . . . . . . . . . . . 89

Tires . . . . . . . . . . . . . . . . . . . . . . 89-91

Wheel Installation . . . . . . . . . . . 91 Wheel Nut Torque . . . . . . . . . . . 90 Wheel Removal . . . . . . . . . . . . . 91 Toe Alignment. . . . . . . . . . . . . . . . . . 85 Towing a Disabled Vehicle . . . . . . . 117 Towing Capacities . . . . . . . . . . . . . . . 63 Towing Loads . . . . . . . . . . . . . . . . . . 63 Training, Safety . . . . . . . . . . . . . . . . . . 7 Transmission . . . . . . . . . . . . . . . . . . . 29 Transmission Oil . . . . . . . . . . . . . 74-75 Transporting the Vehicle . . . . . . . . . 117 Turn Signal Lamp, Front . . . . . . . . . . 96 Turn Signal Lamp, Rear . . . . . . . . . . 96 Turn Signal Switch . . . . . . . . . . . . . . 22 Turning Around on a Hill . . . . . . 54-55 Turning the Vehicle . . . . . . . . . . . . . . 47

V

Vehicle Identification Numbers. . . . . . 5 Vehicle Immersion . . . . . . . . . 100-101

W

Warning Symbols . . . . . . . . . . . . . . . . 6 Washing the Vehicle . . . . . . . . 111-112 Wheel Installation . . . . . . . . . . . . . . . 91 Wheel Nut Torque Specifications . . . 90 Wheel Removal . . . . . . . . . . . . . . . . . 91 132

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