Sign in today to find solutions:

Forgot your password?

Don't have an account? Sign up

 
2003
ATV
Universal
Owner's Manual
for
Vehicle Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.

Summary of Contents

  • Page 1

    2003 Universal Owner's Manual Vehicle Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.

  • Page 2

    WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

  • Page 3

    We’ve created a web site just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...

  • Page 4

    All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

  • Page 5: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 7: Table Of Contents

    NOISE EMISSION CONTROL SYSTEM REGULATION MAINTENANCE AND LUBRICATION POLARIS RECOMMENDED PRODUCTS TROUBLESHOOTING WARRANTY ......

  • Page 8: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 9: Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 10

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury.

  • Page 11

    S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

  • Page 12

    SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 13

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

  • Page 14

    ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING WARNING...

  • Page 15

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.

  • Page 16

    SAFETY Operator Safety POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.

  • Page 17

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.

  • Page 18

    SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.

  • Page 19

    Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

  • Page 20

    SAFETY Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING...

  • Page 21

    Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.

  • Page 22

    SAFETY Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.

  • Page 23

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

  • Page 24

    SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.

  • Page 25

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.

  • Page 26

    SAFETY Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.

  • Page 27

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.

  • Page 28

    SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.

  • Page 29

    Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.

  • Page 30

    SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.

  • Page 31

    Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

  • Page 32

    SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.

  • Page 33

    Operator Safety Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 34

    Warning decals have been placed on the ATV 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.

  • Page 35

    Safety Decals and Locations WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

  • Page 36

    SAFETY Safety Decals and Locations 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. Rear 180 Lbs On models with racks WARNING Moving parts hazard under belt-clutch guard.

  • Page 37

    See your Owner’s Manual. 7079906 2WD Models MANUFACTURED BY: POLARIS IND DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

  • Page 38

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 39: Controls

    Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.

  • Page 40

    This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 41

    If the fluid level is low add DOT 3 brake fluid only. See page 141 for the part numbers of Polaris-recommended products. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 42

    CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.

  • Page 43

    Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

  • Page 44

    CONTROLS Auxiliary Brake Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

  • Page 45

    CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 59 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, either below the fender or on the side panel.

  • Page 46

    CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 47

    Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or mix oil brands. To avoid serious engine damage, always top off the oil level when refueling.

  • Page 48

    CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model. H: High Gear N: Neutral L: Low Gear R: Reverse P: Park Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

  • Page 49

    (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds.

  • Page 50: Features

    FEATURES All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times.

  • Page 51

    All Wheel Drive (AWD) System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

  • Page 52

    FEATURES Indicator Lights The configuration of the indicator lights differs with individual models. Not every model is equipped with all of the lights, and the lights on some models appear in the speedometer. The information in your owner’s manual supplement and on this page will help you identify the lights and their function.

  • Page 53

    Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.

  • Page 54

    FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster. 1. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in: H = High Range L = Low Range N = Neutral R = Reverse...

  • Page 55

    FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode button.

  • Page 56

    FEATURES Instrument Cluster Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off.

  • Page 57

    Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2.

  • Page 58: Operation

    Break-In Period 2-Cycle Engines The break-in period for your new Polaris ATV is defined as the time it takes to use the first tank of fuel. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine.

  • Page 59

    Break-In Period 4-Cycle Engines The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.

  • Page 60

    OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.

  • Page 61

    Starting the Engine Starting a Cold Engine 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.

  • Page 62

    Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

  • Page 63

    OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the weights specified in your owner’s manual supplement. Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible.

  • Page 64

    OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO.

  • Page 65

    Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 66

    Driving Safely Making Turns Some Polaris ATVs are equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 67

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.

  • Page 68

    OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening.

  • Page 69

    Driving Safely Sidehilling Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.

  • Page 70

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single brake lever.

  • Page 71

    Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

  • Page 72

    OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.

  • Page 73

    Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 74

    Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

  • Page 75

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.

  • Page 76: Noise Emission Control System Regulation

    Use caution when traveling through tall grass, especially dry grass. USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. Refer to your owner’s manual supplement for model specific information.

  • Page 77: Maintenance And Lubrication

    Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information. Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.

  • Page 78

    20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Improperly performing the procedures marked with a in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake...

  • Page 79

    6 months 1000 mi. 50 hrs. 6 months 100 hrs. 6 months Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Inspect; replace as needed Inspect monthly; change annually Check terminals; clean; check fluid level Check oil level; change annually Inspect;...

  • Page 80

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl Throttle Cable/ETC Switch Choke (enricher)

  • Page 81

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Fuel system Fuel filter Radiator Cooling system hoses Spark arrestor Front hubs (AWD) " Clutches (drive and driven) Engine mounts Valve clearance (4-Cycle) Oil filter (2-Cycle) Shift selector box (H/L/R) Brake fluid Front wheel bear- ings (2WD) Idle speed Recoil housing...

  • Page 82

    More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLG No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long...

  • Page 83

    MAINTENANCE AND LUBRICATION Lubrication Recommendations...

  • Page 84

    More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.

  • Page 85

    MAINTENANCE AND LUBRICATION Lubrication Recommendations (6) 4 O’clock position (12) (11) (14) (10) (15) (13) (13)

  • Page 86

    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...

  • Page 87

    Premium 2-Cycle Oil Polaris also has a TC-W3 premium oil available for use in all of our 2-cycle products. We highly recommend its use if Premium Gold Synthetic is not used.

  • Page 88

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40.

  • Page 89

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug, which is located on either the bottom of the oil tank or on the bottom of the engine. 3.

  • Page 90

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 11. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

  • Page 91

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4, Magnum 330 4x4, Trail Boss 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug (1). 3. Run the engine for two to three minutes until warm.

  • Page 92

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4, Magnum 330 4x4, Trail Boss 12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place the gear selector in neutral and set the parking brake.

  • Page 93

    2. Use the gearcase oil fill chart and the following illustration to determine correct fluid levels. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. See page 141 for the part numbers of Polaris-recommended products. Gearcase Oil Fill Chart...

  • Page 94

    Catch and discard used oil properly. 4. Clean and reinstall the drain plug torque to 14 ft. lbs. (19 Nm). 5. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant. Refer the the gearcase oil fill chart on page 91 for proper oil levels.

  • Page 95

    2. Reinstall the dipstick completely, then remove it and check the level. Add the proper lubricant as required to bring level into the safe operating range. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. See page 141 for the part numbers of Polaris-recommended products.

  • Page 96

    Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add 32 oz. (948 ml) of Polaris Premium Synthetic Gearcase Lubricant to the full mark on the fill plug/dipstick. Maintain the oil level in the safe operation range (1).

  • Page 97

    The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 141 for the part numbers of Polaris-recommended products.

  • Page 98

    (1). Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8″ below the top of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 141 for the part numbers of Polaris-recommended products.

  • Page 99

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Counter Balance Oil Check - 400 2-Cycle Engines The counter balance oil should be checked semi-annually and oil should be added or changed as needed. The oil should be changed annually and before off season storage. If the machine is used in wet conditions, check the oil more frequently.

  • Page 100

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank is located either on the left side of the vehicle (external tank models)(1) or on the engine (2). 1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine. 3.

  • Page 101

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 141 for the part numbers of Polaris-recommended products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations...

  • Page 102

    MAINTENANCE AND LUBRICATION Engine Cooling System Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair.

  • Page 103

    NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.

  • Page 104

    MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 250 Engines 1. Before adjusting the oil pump, check the engine idle RPM and carburetor settings in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn the adjuster (1) in or out until there is 1/16″...

  • Page 105

    MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments in your owner’s manual supplement. 2. Loosen the throttle cable jam nut and turn the adjuster in or out until there is 1/16″...

  • Page 106

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (see page 141). 2. Check the brake system for fluid leaks.

  • Page 107

    MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be changed when worn to 3/64″...

  • Page 108

    (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING...

  • Page 109

    Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.

  • Page 110

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.

  • Page 111

    +40 degrees F. (4 degrees C.) NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. 2-Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.

  • Page 112

    MAINTENANCE AND LUBRICATION Adjustments Carburetor 4-Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for approximately five minutes. 2. Place the transmission in gear with the parking brake applied.

  • Page 113

    MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal - Gen IV NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab.

  • Page 114

    MAINTENANCE AND LUBRICATION Adjustments Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual supplement.

  • Page 115

    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

  • Page 116

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less.

  • Page 117

    MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers.

  • Page 118

    MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack - Concentric Drive Models Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications.

  • Page 119

    MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack - Concentric Drive Models 6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 7. Tighten the eccentric locking bolts to 30 ft.

  • Page 120

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service - 2-Cycle Engines 1. Remove the ATV seat. 2. Release the clips securing the cover assembly to the air box. 3. Loosen the clamp securing the filter, and remove the filter. 4.

  • Page 121

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service - 4-Cycle 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 122

    MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 123

    MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Trail Blazer 1. Remove the front cover and unplug the light harness. 2. Remove the rubber cap from the back of the headlight to reveal the retention screw. 3. Remove the small phillips head screw, and carefully remove the bulb from the housing.

  • Page 124

    MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Gen IV 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. 3.

  • Page 125

    MAINTENANCE AND LUBRICATION Lights High Beam Adjustment - Gen IV The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft.

  • Page 126

    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement - Gen IV 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs.

  • Page 127

    MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and replace it with a new lamp.

  • Page 128

    Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 129

    MAINTENANCE AND LUBRICATION Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 130

    MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 131

    MAINTENANCE AND LUBRICATION Spark Arrestor 1. Remove the arrestor clean-out plug(s) (1) from the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4.

  • Page 132

    MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.

  • Page 133

    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt.

  • Page 134

    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.

  • Page 135

    MAINTENANCE AND LUBRICATION Battery (Conventional) Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

  • Page 136

    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery.

  • Page 137

    MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in the battery holder. 2. With conventional batteries, install the battery vent tube. Sealed batteries do not have a vent tube. NOTE: The vent tube must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion.

  • Page 138

    MAINTENANCE AND LUBRICATION 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. NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.

  • Page 139

    Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 140

    Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation...

  • Page 141

    See page 141 for the part numbers of Polaris-recommended products. Fog the Engine 2 Cycle - Use Polaris Fogging Oil and follow the directions on the can. 4-Cycle - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil.

  • Page 142

    Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 143: Polaris Recommended Products

    POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.)

  • Page 144: Troubleshooting

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. fuel lines, or carburetor. Contact your dealer for service.

  • Page 145

    Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...

  • Page 146

    Incorrect jetting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...

  • Page 147

    Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.5 VDC...

  • Page 148: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV.

  • Page 149

    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.

  • Page 150

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 151: Index

    Accessories ......Adjustments ......Age Restrictions .

  • Page 152

    ..... Periodic Maintenance Schedule POLARIS RECOMMENDED PRODUCTS Pre Ride Inspection ..... . .

  • Page 153

    Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE AN APPROVED ON PUBLIC HELMET AND PROTECTIVE GEAR NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions.

Comments to this Manuals

Symbols: 0

Latest comments:

×

Select the desired size and copy embed code

Copy your embed code and put on your site: