Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 6 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. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles...
Page 7 WELCOME We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
Page 8: Table Of Contents
CLEANING AND STORAGE TROUBLESHOOTING POLARIS PRODUCTS SPECIFICATIONS ..........
Page 9: Know Your Vehicle
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.
Page 10 KNOW YOUR VEHICLE Vehicle Identification Numbers 31XX Vehicle Model Number: Frame VIN (1)(left side): Engine Serial Number (2)(right side): Key Number (3):...
Page 11: Safety
ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
Page 12: Safety Decals And Locations
S avoid paved surfaces -- pavement may seri- ously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. SAFETY...
Page 13 SAFETY Safety Decals and Locations Age 16 Warning (2) WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age Sport ATV Warning (3) WARNING This ATV may exceed the performance of other ATVs you may have ridden in the past.
Page 14 Safety Decals and Locations No Passenger Warning (5) WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load Warning (6) IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
Page 15: Safe Riding Gear
1. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S.
Page 16 Safe Riding Gear 2. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V- -8, Z87.1, or CE.
Page 17: Operator Safety
Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Page 18: Safety Training
You should review this information on a regular basis. If you purchased a used Polaris ATV, you can take the ATV RiderCourse ATV Enrollment Express at (800) 887-2887 available to or by visiting www.atvsafety.org.
Page 19 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
Page 20 SAFETY Operator Safety CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. NOTE: A note will alert you to important information or instructions.
Page 21 S Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for...
Page 22 Operator Safety S Never operate an ATV on a public street, road or highway, including a dirt or grav- el road. S Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long- sleeved shirt or jacket, and long pants.
Page 23 Do not turn at excessive speeds. S Always have the ATV inspected by an authorized Polaris dealer if it’s been in- volved 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 24 Operator Safety S Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose sur- faces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual.
Page 25 FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atv- safety.org, or call Polaris at 1-800-342-3764. S Always check for obstacles or people be- hind the ATV before operating in re- verse.
Page 26: Equipment Modifications
The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
Page 27 Owner’s Manual. For more information about the ATV RiderCourse at (800) 887-2887 or visit www.atvsafety.org offered by Polaris through the SVIA. They should contact ATV Enrollment Express...
Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD: Only operators with advanced skills and substantial experience should operate this ATV.
Page 29 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. Only operators with advanced skills and substantial experience should operate this ATV.
Page 30 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 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN: ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.
Page 32 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 33 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN: Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
Page 34 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN: Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
Page 35 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Attempting 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 jumps or other stunts. Avoid exhibition driving.
Page 36 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN: Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD: Always inspect your ATV before each use to make sure it’s in safe operating condition.
Page 37 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN: Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footpeg, it could come into contact with the rear wheels and lead to accident or injury.
Page 38 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN: Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Travel slowly and use extra caution when operating on unfamiliar terrain.
Page 39 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 40 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Turning improperly. WHAT CAN HAPPEN: Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
Page 41 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 42 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Traveling downhill improperly. WHAT CAN HAPPEN: Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
Page 43 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 44 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Stalling, rolling 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 45 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Improperly operating over obstacles. WHAT CAN HAPPEN: Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
Page 46 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN: Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD: Avoid operating the ATV through deep or fast-flowing water.
Page 47 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN: Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD: Always use the size and type of tires specified for the ATV in the owner’s manual.
Page 48 HOW TO AVOID THE HAZARD: Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your...
Page 49 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating on frozen bodies of water. WHAT CAN HAPPEN: Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD: Never operate the ATV on a frozen body of water. WARNING POTENTIAL HAZARD Improperly operating in reverse.
Page 50 SAFETY Operator Safety WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
Page 51: Features And Controls
FEATURES AND CONTROLS Engine Electrical Switches...
Page 52 Engine Electrical Switches Start Button - The start button engages the starter. Always release the start button as soon as the engine starts. Engine Stop Switch - The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of an emergency.
Page 53 FEATURES AND CONTROLS Instrumentation An illuminated light in the indicator window will alert you to the following conditions. 1. Hot engine 2. Reverse gear is selected 3. Neutral gear is selected...
Page 54 Lights WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
Page 55: Throttle Lever
FEATURES AND CONTROLS WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
Page 56: Clutch Lever
Throttle Lever Electronic Throttle Control 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 57: Foot Brake
FEATURES AND CONTROLS Foot Brake The foot brake (1) operates the rear brakes. It’s located in front of the right-hand footpeg (2). If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding. Check the brake fluid level frequently for the foot brake system.
Page 58: Brake Lever
Brake Lever The brake lever operates the front brakes. It’s located on the right handlebar. Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes. Always test brake lever travel and master cylinder fluid level before riding.
Page 59: Master Cylinder
When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 4 brake fluid only. Do not overfill. See page 183 for the part numbers of Polaris products.
Page 60 FEATURES AND CONTROLS Master Cylinder 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. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
Page 61: Parking Brake
FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1.
Page 62 Parking Brake Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill.
Page 63: Fuel Filter
87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged.
Page 64: Fuel Valve
Fuel Valve The fuel valve (1) is located on the left side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. FUEL There’s about a 5 to 8 mile (8 to 13 km) range NOTE: on reserve gas.
Page 65 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. The choke knob (1) is located on the left side of the vehicle. Refer to the engine starting procedure on page 72 for correct choke and throttle settings during starting.
Page 66 Manual Shift Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released. To upshift to a higher gear, place the toe of your boot under the gear shift pedal and raise the pedal one full stroke.
Page 67: Shifting Gears
FEATURES AND CONTROLS Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral. 2. Squeeze and hold the brake lever. NOTE: Do not squeeze the throttle lever. 3.
Page 68: Reverse Lock-Out Switch
Manual Shift Reverse Lock-Out Switch The reverse lock-out switch (1) prevents the operator from shifting into reverse unintentionally. 1. Place the transmission in first gear. See page 63. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3.
Page 69 FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear.
Page 70: Operation
Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenev- er handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 71: Break-In Period
Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris ATV is defined as the first one hour of operation, or the time it takes to use the first full tank of gasoline.
Page 72 Break-In Period 1. Fill the fuel tank with gasoline. See page 60. 2. Check the oil level on the dipstick. See page 103. Add oil if necessary to maintain the level between the safe and add marks. 3. Allow the engine sufficient time to warm up before operating. 4.
Page 73: Pre-Ride Inspection
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Item Brake system / lever travel Brake fluid Foot brake Clutch lever...
Page 74 Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Check operation, apply Polaris dielectric grease to the socket when the lamp is replaced Check operation, adjust brake light switch Wear helmet, goggles, protective clothing Check freeplay. If the tire moves excessively, do not operate.
Page 75 OPERATION Starting a Cold Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. 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.
Page 76: Starting A Cold Engine
Starting a Cold Engine 3. Sit on the ATV. Pull the choke knob (1) out until it stops. NOTE: If the knob doesn’t stay where positioned, increase the tension by rotating the tension adjusting nut clockwise. FULL ON HALF ON NOTE: The choke can be adjusted gradually, depending on how much choke is needed for starting.
Page 77 OPERATION Starting a Cold Engine NOTE: If starting the engine while in neutral, the neutral indicator light should be on. If it isn’t, disengage the clutch and shift the foot pedal to find neutral. See page 63. If starting the engine while in gear, apply the hand brake and squeeze the clutch lever fully to disengage the clutch.
Page 78: Starting A Warm Engine
Release the throttle lever immediately after the engine starts. If the engine does not start, review the engine troubleshooting information beginning on page 176. If all conditions are favorable and the engine still does not start, see your Polaris dealer for service.
Page 79: Driving Safely
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. See page 64. 3. Check your surroundings and determine your path of travel.
Page 80: Making Turns
Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turning, and the inside tire slips traction slightly.
Page 81: Driving On Slippery Surfaces
OPERATION 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 82: Driving Uphill
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 footpegs and transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening.
Page 83: Driving Across Hills
OPERATION Driving Safely Driving Across Hills WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. If you enter into a situation where sidehilling is unavoidable: 1.
Page 84: Driving Downhill
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. Shift to the lowest gear possible while maintaining a safe speed. 5.
Page 85 OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
Page 86 Driving Safely Turning Around on a Hill 5. Staying uphill of the ATV, turn the handlebars full left. Reach across the handlebar and apply the front brakes to unlock the parking brake. 6. With the front brakes applied, pull in the clutch lever.
Page 87 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
Page 88: Driving Over Obstacles
Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
Page 89 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.
Page 90: Driving Through Water
Driving Safely Driving Through Water CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footpeg level, take it to your dealer for service before starting the engine.
Page 91 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Back slowly. 3. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly while backing.
Page 92: Driving In Reverse
Before shifting into reverse, always check for obstacles or people behind the vehicle. Drive slowly. Avoid backing on inclines. Avoid turning at sharp angles. NOTE: This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use just enough throttle to maintain a desired speed. CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.
Page 93: Emission Control Systems
Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
Page 94: Crankcase Emission Control System
The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
Page 95: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the following pages. A tool kit is provided in the storage compartment under the seat. Keep the tool kit with the vehicle at all times.
Page 96: Periodic Maintenance Schedule
S Short trip cold weather operation Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Page 97 Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special could result in component...
Page 98: Periodic Maintenance Chart
Inspect; maintain fluid between fill lines Inspect Inspect; tighten Inspect; tighten Inspect; clean; replace as needed Inspect level; add as needed Fill to proper levels Fill to proper level with Polaris PS-4 oil Check operation Check operation and adjustment Check operation Check operation...
Page 99 " Rear shaft assembly Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Polaris Premium All Season Grease Maintenance Interval (whichever comes first) Calendar Miles (Km)
Page 100 Periodic Maintenance Chart Item Hours Air filter, " main element Brake pad wear Oil Change " Oil Filter " Battery Engine breather filter " General lubrication " MAINTENANCE AND LUBRICATION Maintenance Interval (whichever comes first) Calendar Miles (Km) Weekly 10 H Monthly 100 (160) 10 H...
Page 101 " and filter (in airbox) Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Polaris Premium All Season Grease Maintenance Interval (whichever comes first) Calendar Miles (Km)
Page 102 Periodic Maintenance Chart Item Hours Upper steering " post (A) Front A-Arms (B) " Rear Control Arm " Bushings (C) Stabilizer Bar (D) " Rear Control Arm " Needle Bearings (E) MAINTENANCE AND LUBRICATION Maintenance Interval (whichever comes first) Calendar Miles (Km) 50 H 500 (800)
Page 103 100 H Ignition Timing Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Polaris Premium All Season Grease Maintenance Interval (whichever comes first) Calendar Miles (Km)
Page 104 Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Polaris Premium All Season Grease MAINTENANCE AND LUBRICATION Maintenance Interval (whichever comes first)
Page 105: Lubrication Recommendations
Lubrication Recommendations Performance Synthetic 4-Stroke (PS-4) Oil Polaris highly recommends the use of Polaris PS-4 or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. PS-4 has been specifically formulated for use in high performance engines. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection and prolonged clutch life.
Page 106 Engine Oil Level Check the oil level before each use of the vehicle. The dipstick (1) is located on the left side of the ATV. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for one minute. 3.
Page 107: Engine Oil Level
MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.
Page 108: Oil And Filter Change
Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filter within a few hours of draining the oil.
Page 109 MAINTENANCE AND LUBRICATION Oil and Filter Change 1. Position the vehicle on a level surface. 2. Clean the area around the oil tank (1) and crankcase (2) drain plugs with clean shop towels. 3. Run the engine for two to three minutes until warm, then stop the engine.
Page 110 Oil and Filter Change 7. Place a drain pan beneath the crankcase and remove the drain plug. 8. Allow the oil to drain completely. 9. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm). 10.
Page 111 MAINTENANCE AND LUBRICATION Oil and Filter Change 14. Replace the o-ring in the cover. 15. Lubricate the gasket on the new filter with a film of fresh engine oil. 16. Reinstall the spring and install the new filter with the open end facing outward. 17.
Page 112 Oil and Filter Change 18. Remove the dipstick and fill the oil tank with the recommended oil. 19. Place the transmission in neutral. Lock the parking brake. 20. Prime the oil pump using the procedure on page 110. Then stop the engine and inspect for leaks.
Page 113: Oil Pump Priming
MAINTENANCE AND LUBRICATION Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I (5 cm) from the oil tank. 2.
Page 114: Engine Cooling System
See page 183 for the part numbers of Polaris 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 for the freeze...
Page 115 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL (2) and ADD (3) marks on the side panel (when the fluid is cool).
Page 116 Engine Cooling System WARNING 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 cap. Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and/or repair.
Page 117: Air Filter Systems
MAINTENANCE AND LUBRICATION Air Filter Systems 1. Unlatch and remove the seat. 2. Release the two airbox cover clips (1) and rotate the cover rearward to remove it. 3. Remove the air filter retaining screw (2). 4. Loosen the filter clamp (3). 5.
Page 118 Air Filter Systems 9. Wash the main filter element (4) without removing it from the internal filter cage. Rinse and let dry. 10. Apply a commercially available foam filter lubricant to the foam filter. 11. Reinstall all components. 12. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. CAUTION Operation of your vehicle without a breather filter can cause engine damage.
Page 119 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
Page 120: Headlight Lamp Replacement
Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise (1) to remove the bulb. On the right headlamp, turn the bulb housing clockwise (2) to remove the bulb.
Page 121 MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 121). 3. Remove the small adjuster bracket (1). Install it on the new lamp. 4. Remove the large pivot bracket (2) and remove the headlamp. 5.
Page 122: Headlight Adjustment
Lights Headlight Adjustment 1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
Page 123: Brake Light Adjustment
MAINTENANCE AND LUBRICATION Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle. 1. Turn the ignition key on. 2. Lightly apply and release the foot brake several times. A properly operating rear brakelight will immediately flash on and off with each movement of the brake pedal.
Page 124: Side Panel Removal
Front Cab Removal 1. Remove the screws (1) from the left and right cab mounts. 2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2). 4.
Page 125 MAINTENANCE AND LUBRICATION Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab and the two bolts (2), washers and grommets (3) on the top of the cab. 3.
Page 126: Spark Plugs
CAUTION Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. 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 127 MAINTENANCE AND LUBRICATION Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.
Page 128 Spark Plugs Spark Plug Removal and Replacement 1. Remove the side panels and front cab (see page 121). 2. Turn the fuel valve off. WARNING A hot ember on the ATV could cause fuel to ignite. Allow all components to cool sufficiently before accessing the spark plug.
Page 129 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting on the gas tank. 4. Remove the vent hose (2) from the steering post, taking note of the hose routing for reinstallation.
Page 130 Spark Plugs Spark Plug Removal and Replacement 5. Remove the tank mounting bolt (3) at the rear of the gas tank. 6. Move the tank rearward and upward over the engine. Slowly remove the tank and be careful not to catch any hoses, wires or other components. Place the tank on a stable surface or work bench.
Page 131 MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Wear eye protection and gloves. Never run the engine in an enclosed area.
Page 132 Spark Arrestor Clean-Out Periodically clean the spark arrestor to remove accumulated carbon. Your vehicle has either an end cap-type arrestor or a set screw-type arrestor. Perform the appropriate clean-out procedure for your arrestor type. End Cap-Type Arrestor 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler.
Page 133 MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out Set Screw-Type Arrestor 1. Remove the bolt (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components are warm.
Page 134: Vehicle Immersion
Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it’s critical to dry it promptly and properly before starting the engine. CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended depth.
Page 135 MAINTENANCE AND LUBRICATION Vehicle Immersion 1. Turn the fuel valve off. 2. Drain water from the air box and clean the air filter (if equipped). See page 114. 3. Drain the fuel/water from the carburetor for about 10 seconds. 4. Remove the spark plug. See page 125. WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts.
Page 136 Vehicle Immersion 6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole. 7. Check the oil level on the dipstick. If the level is higher than the pre-ride inspection level, water has entered the oil tank.
Page 137 MAINTENANCE AND LUBRICATION 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. Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.
Page 138: Battery Removal
MAINTENANCE AND LUBRICATION Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed and stored out of the sun in a cool, dry place. Test and recharge the battery monthly and before reusing. Battery Removal 1.
Page 139: Battery Installation
MAINTENANCE AND LUBRICATION Battery Installation 1. Place the battery in the battery holder. 2. Connect and tighten the red (positive) cable first, then connect and tighten the black (negative) cable. 3. Attach the hold-down strap and reinstall the front cab. 4.
Page 140 Removing the cab is not necessary. NOTE: The Polaris Battery Tendert battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 141 MAINTENANCE AND LUBRICATION Battery Charging (Sealed Battery) When using an automatic charger such as the Polaris Battery Tendert, refer to the manufacturer’s instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging.
Page 142 Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after charging. State of Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less MAINTENANCE AND LUBRICATION Voltage None, check at 3 mos.
Page 143 MAINTENANCE AND LUBRICATION Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the ATV decal and in the owner’s manual.
Page 144: Wheel Removal
Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less. See illustration. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3.
Page 145: Wheel Installation
MAINTENANCE AND LUBRICATION Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Never install the rim with the valve stem to the inside of the vehicle. Always ensure that all nuts are torqued to specification. 1.
Page 146 Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. Bolt Size Front 3/8″ Rear 3/8″ MAINTENANCE AND LUBRICATION Torque Specification 30-35 ft. lbs. (40-47 Nm) 30-35 ft. lbs. (40-47 Nm)
Page 147: Boot Inspection
Before Operating Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, see your Polaris dealer for service or replacement. Good Boot After Operating Inspect the boots after operating the vehicle. If a boot is bulging or ballooned, perform the boot burping procedure on page 145.
Page 148: Boot Burping
Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape.
Page 149: Adjustments
ADJUSTMENTS Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation.
Page 150 Brakes 1. Always keep brake fluid at an adequate level. See page 56. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5.
Page 151: Toe Alignment
Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check toe alignment. The vehicle is designed for a neutral toe setting.
Page 152 6. Measure the distance from the string to the rim at the front and rear of the front rim (3). The difference between these two measurements should be between 0″ and 1/16″ (0-1.5 mm) toe out. NOTE: If you discover improper alignment, see your Polaris dealer for service. ADJUSTMENTS...
Page 153: Chain Tension
ADJUSTMENTS Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain.
Page 154 Chain Tension 1. Loosen the upper and lower pivot mounting bolts (1). 2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4.
Page 155 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Loosen the four handlebar bolts (1).
Page 156: Steering Assembly
The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the steering post, see your Polaris dealer for service before operating the vehicle. Camber and Caster...
Page 157: Front Suspension
ADJUSTMENTS Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.
Page 158 Front Suspension Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8.
Page 159 WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments.
Page 160 Front Suspension Spring Preload 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring (1) clockwise to increase preload (A). Turn the ring counter-clockwise to decrease preload (B). ADJUSTMENTS...
Page 161: Rear Suspension
ADJUSTMENTS Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the rear of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.
Page 162 Rear Suspension Suspension Set-Up 5. Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7.
Page 163 ADJUSTMENTS Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the softest position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments. Rear Shock Setting Compression Damping Softest...
Page 164 Rear Suspension The rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend. 2.
Page 165: Compression Damping
Rear Suspension Compression Damping The compression damping clickers (1) are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From this position, turn the screw clockwise to increase compression damping.
Page 166: Clutch Lever Freeplay
ADJUSTMENTS Clutch Lever Freeplay 1. Measure clutch lever freeplay between the perch and the lever (A). This distance should be 1/8″ - 3/16″ (3-4.7 mm). 2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw (B) and lock ring (C).
Page 167: Throttle Cable Freeplay
WARNING Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it’s done correctly. Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly.
Page 168 Carburetor/Idle RPM 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 five minutes, or until operating temperature is reached. 2. Apply the parking brake and place the transmission in neutral.
Page 169 ADJUSTMENTS Carburetor/Idle RPM Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich.
Page 170: 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. CAUTION 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.
Page 171: Washing The Vehicle
CLEANING AND STORAGE Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
Page 172 S Transmission seals S Brakes 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.
Page 173: Polishing The Vehicle
CLEANING AND STORAGE 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 S Avoid the use of automotive products, some of which can scratch the finish of your ve- hicle.
Page 174 Make any necessary repairs and clean the vehicle as recommended. See page 167. Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank, following the instructions on the container for the recommended amount. Fill the fuel tank with fuel.
Page 175 CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter. See page 105. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.
Page 176 3. Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor. 4. Start the engine and spray Polaris fogging oil or a comparable product into the carburetor, following the instructions on the fogging oil container.
Page 177 Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to...
Page 178: Transporting The Atv
Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly.
Page 179: Troubleshooting
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Fuseable link Low battery voltage Loose battery connections Loose solenoid connections Solution See Polaris dealer for replacement Recharge battery to 12.8 VDC...
Page 180 Turn the fuel valve on Drain and replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Inspect, clean and/or replace spark plugs Recharge battery to 12.8 VDC See your Polaris dealer Adjust throttle freeplay...
Page 181 Incorrectly installed spark plug wire Incorrect ignition timing Mechanical failure Solution Replace with recommended fuel See your Polaris dealer Set gap to specs or replace plugs Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs...
Page 182 Electronic throttle control (ETC) malfunction Other mechanical failure TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC or replace...
Page 183 Plugged, dirty or wet air filter Solution Add or change fuel, clean the fuel system Replace with recommended fuel Replace with recommended fuel See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs Replace with recommended lower octane fuel...
Page 184 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 12.8 VDC or replace...
Page 185: Engine Overheating
Engine Overheating Possible Cause Debris lodged in screen Plugged radiator Solution Inspect and clean or replace See your Polaris dealer See your Polaris dealer Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Solution Remove and clean the screen.
Page 186: Polaris Products
2871460 Starter Drive Grease (2 oz.) 2871329 Dielectric Grease (Nyogelt) 2872073 Chain Lube (6.25 oz. aerosol) 2872348 Chain Lube (16 oz. aerosol) 1350046 Rear Shaft Grease (30 g) POLARIS PRODUCTS Part # Description Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.)
Page 187: Specifications
SPECIFICATIONS Gross Vehicle Weight 645 lbs./292 kg Fuel Capacity 3.25 gal./12.3 l Overall Length 71.5 in./182 cm Overall Width 47.5 in./121 cm Overall Height 45 in./114 cm Wheelbase 51 in./130 cm Ground Clearance 11.5 in./29 cm Dry Weight 439 lbs./199 kg Minimum Turning Radius 67 in./170 cm Engine Oil Capacity...
Page 188: Jetting Chart
Driving System Type Rear Two-Wheel Drive Shift Type 5-Speed Manual Shift Primary Ratio 2.880 Gear Ratio - 1st 2.429 Gear Ratio - 2nd 1.611 Gear Ratio - 3rd 1.286 Gear Ratio - 4th 1.087 Gear Ratio - 5th 0.920 Gear Ratio - Rev 2.072 Jetting Chart Altitude...
Page 189: Warranty
Polaris dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
Page 190 ATV due to fire, explosions or any other cause beyond Polaris’ control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV.
Page 191 ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an...
Page 192: Engine Oil
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 193 LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warran- ty or service bulletin coverage if you have any questions.
Page 194 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
Page 195 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce- dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
Page 196 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
Page 197 U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or re- placement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
Page 198: Maintenance Log
Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Date Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Dealer or Person MAINTENANCE LOG Remarks...
Page 199 MAINTENANCE LOG Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...
Page 200 MAINTENANCE LOG Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...
Page 201: Index
INDEX Age Restrictions ... . Air Filter Systems ..114-115 Battery ....Battery Charging, Sealed Battery .
Page 202 ... . 58-59 Parking on an Incline ..Polaris Products ... Polishing the Vehicle ..

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