1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. ATV 2002
  6. Owner's manual

Polaris ATV 2002 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Polaris ATV 2002

Summary of Contents for Polaris ATV 2002

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm. A card containing important safey 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 as- sistance.
  • Page 3 WARNING Indicates a potential hazard that could result in serious injury or death.
  • Page 4 We’ve created a web site, just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 5 Your Owner’s Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician. Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction.

  • Page 6: Safety Training

    You should review this information on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Vehicle Identification Numbers ....Safety ....... . . 7 - 42 Understanding Warnings .
  • Page 8 TABLE OF CONTENTS Maintenance and Lubrication ..88 - 168 Periodic Maintenance Schedule ....Lubrication Recommendations .

  • Page 9: Vehicle Identification Numbers

    2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key.

  • Page 10: Safety

    SAFETY Understanding Warnings 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 11: Key Safety Issues

    All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.
  • Page 12 S Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident.
  • Page 13 SAFETY Key Safety Issues S Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill.
  • Page 14 Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes.

  • Page 15: Decals And Locations

    Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.

  • Page 16: Safety Decals And Locations

    SAFETY Safety Decals and Locations WARNING IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT. 7079083 E1997, 2000...
  • Page 17 SAFETY Safety Decals and Locations...
  • Page 18 SAFETY Safety Decals and Locations WARNING UNDER 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 16. 7078253 WARNING 25° F Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.
  • Page 19 SAFETY Safety Decals and Locations...
  • Page 20 SAFETY Safety Decals and Locations (on rear of seat) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT ___ REAR ___ MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS. Reduce speed and allow greater distance for braking when carrying cargo.
  • Page 21 SAFETY Safety Decals and Locations (Under Seat) ATTENTION D Specific carburetor jetting D Operation of this and adjustments are vehicle without the required depending on temperature filter element will severely and altitude. See your Owner’s Manual. damage the engine. Factory setting: D Clean air filter often, more 40_ to 80_ F.
  • Page 22 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 7070021...

  • Page 23: Override Switch

    SAFETY Safety Decals and Locations MANUFACTURED WARNING BY: POLARIS IND OVERRIDE Pushing reverse SWITCH DATE: override button may cause Reverse Speed is sudden in- VIN: limited. creases in pow- er and traction if THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND...

  • Page 24: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.

  • Page 25: Operator Safety

    ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.
  • Page 30 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 32 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 33 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 34 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills...
  • Page 35 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. See page 78 . Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 36 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 80 through 83. Always check the terrain carefully before you start up any hill.
  • Page 37 SAFETY Operator Safety WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 82. NOTE: A special technique is required when braking as you go downhill.
  • Page 38 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground.
  • Page 39 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 40 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 41 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this 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. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water.
  • Page 42 Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have...
  • Page 43 SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to 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 44 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.

  • Page 45: Safety

    SAFETY Operator Safety WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this rider active vehicle requires good judgement and physical skills.

  • Page 46: Features And Controls

    CONTROLS AND FEATURES Controls Engine Electrical Switches WARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death. 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse RUN OFF speed limiter system.

  • Page 47: Throttle Lever

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

  • Page 48: Controls And Features

    CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir fluid level before riding.

  • Page 49: Front And Rear Brakes

    CONTROLS AND FEATURES Controls WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Front and Rear Brakes The brake fluid in the master cylinder, which is located on the...

  • Page 50: Parking Brake

    CONTROLS AND FEATURES Controls Parking Brake WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated.

  • Page 51: Auxiliary Brake

    Your Polaris ATV has an auxiliary brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot.

  • Page 52: Fuel System

    “on” position after refueling machine. Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.
  • Page 53 CONTROLS AND FEATURES Controls Engine Fuel and Oil System WARNING 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 54 Controls Engine Fuel and Oil System CAUTION On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. To avoid serious engine damage always top off the oil level when refueling.
  • Page 55 CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your machine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter.

  • Page 56: Manual Shift

    CONTROLS AND FEATURES Controls Manual Shift The engine can only Gear Shift Pedal be started with the transmission in neutral. Turn the key to “on” and ensure the stop switch is in the run position. The neutral indicator light should be on. If it is not, shift the foot pedal down ( or up and down, if in...

  • Page 57: Shift Pedal

    CONTROLS AND FEATURES Controls Shift Pedal The gear shift pedal is above the left floorboard. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence. The pedal automatically returns to the horizontal position when released.
  • Page 58 CONTROLS AND FEATURES Controls Shifting to Reverse With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control. Depress the gear shift pedal one stroke. The reverse indicator light will come on. Slowly release the brake lever and press throttle control lightly.
  • Page 59 CONTROLS AND FEATURES Controls Shifting From Reverse to Forward Be sure machine is completely stopped. Hold the brake lever, raise gear shift pedal one full stroke to engage forward gear. NOTE: neutral is bypassed when shifting from reverse to 1st gear. To engage neutral, depress gear shift pedal one full stroke from the 1st gear position.

  • Page 60: Recoil Starter

    (A) located on the right side of the machine will allow vehicle operation until repairs can be made. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting.

  • Page 61: Features

    CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off”...

  • Page 62: Disengaging Wheel Hubs

    CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch Disengaging Wheel Hubs When backing up while in Demand 4 Drive and then going forward, one or both hubs may remain engaged.

  • Page 63: Indicator Lights

    CONTROLS AND FEATURES Features Indicator Lights Each Polaris ATV has indicator lights. The configuration of these lights differs with individual models and not every model is equipped with all the lights. The information in your Owner’s Manual Supplement and in the information on this page will help you identify the lights on your machine and their function.
  • Page 64 Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilometers as well as hours of operation.
  • Page 65 CONTROLS AND FEATURES Features Electronic Speedometer When the programmed hours are reached, SEr hr will light; when the programmed distance is reached, SErdIS will light. Each time the vehicle is started, the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next service interval.
  • Page 66 CONTROLS AND FEATURES Features Electronic Speedometer Setting Service Hours (cont.) 6. Repeat step 4 and 5 to program the digits for the service interval selected. (i.e. for service interval of 50 hours set the display to show: 00050 H) 7. To save the changes press and hold the button when any one of the digits is flashing.
  • Page 67 CONTROLS AND FEATURES Features Electronic Speedometer To Set Service Distance Same as setting Service Hours, but toggle to SET dIS. To Check When Service Is Due By Distance Same as setting Service Hours, but toggle to SET dIS. To Clear The Service Reminder From The Display The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval.

  • Page 68: Auxiliary Power Outlet

    On select models, an outlet is located on the front headlight pod. To determine if your vehicle is equipped with auxiliary power outlet, please check your Owner’s Manual Supplement. Accessory outlets are available for all models. Contact your Polaris dealer for more information.

  • Page 69: Operation

    OPERATION Pre Ride Inspection WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.

  • Page 70: Vehicle Break-In Period

    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 gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine.
  • Page 71 OPERATION Break-In Period After the break in period the oil injection system provides the necessary engine lubrication without the need for pre-mixed fuel. CAUTION Fill the oil tank when you refuel your ATV. If you don’t serious engine damage could result. After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pump is functioning properly.
  • Page 72 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 tanks full of gasoline. No single action on your part is as important as a proper break in period.

  • Page 73: Starting The Engine

    OPERATION Starting the Engine Procedure for Starting a Cold Engine WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result.
  • Page 74 Then push the choke all the way Cold Weather Operation - 4 Cycle Engines Polaris offers the following kits for cold weather operation: Oil Tank Cover, Engine Heater and Oil Tank Heater. These kits reduce moisture accumulation in the oil tank when the ATV is operated in freezing temperatures.

  • Page 75: Carrying Loads

    OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
  • Page 76 OPERATION Carrying Loads WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. 2/3 of Load on 1/3 of Load on Rear Rack...
  • Page 77 OPERATION Carrying Loads LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable oper- ating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

  • Page 78: Noise Emission Control System

    S Be especially careful when traveling through tall grass. The poten- tial for fire exists. USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your model, see the Owner’s Manual...

  • Page 79: Riding

    RIDING Pre Ride Inspection WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.

  • Page 80: Safe Riding Tips

    RIDING Safe Riding Tips 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 81: Making Turns

    Making Turns Practice making turns at slow speeds. 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 82: Riding On Slippery Surfaces

    RIDING Safe Riding Tips Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special atten- tion must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2.

  • Page 83: Traveling Uphill

    RIDING Safe Riding Tips Traveling Uphill 25_ Maximum WARNING Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1.
  • Page 84 RIDING Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2.

  • Page 85: Traveling Downhill

    RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs.

  • Page 86: Turning Around On A Hill

    RIDING Safe Riding Tips Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.

  • Page 87: Crossing Streams

    RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines.

  • Page 88: Trail Obstacles

    RIDING Safe Riding Tips Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Not all obstacles are visible.

  • Page 89: Backing Up

    6. Never activate override button while throttle is open. Loss of control may result. 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. Only open the throttle enough to maintain a desired speed.

  • Page 90: Parking On An Incline

    RIDING Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in gear or in park. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

  • Page 91: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

  • Page 92: Periodic Maintenance Schedule

    Pre-ride Drain deposits whenever " Tube visible Headlamp Inspection Pre-ride Pre-ride Check operation daily; ap- ply Polaris dielectric grease to connector when replaced Tail lamp inspection Pre-ride Pre-ride Check operation daily; ap- ply Polaris dielectric grease to socket when re-...
  • Page 93 Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 94 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Remarks Miles Oil Filter(4-Cycle) 100 hrs / Replace with oil change " 1000 months miles Oil Pump Cable 50 hrs Inspect, adjust, lubricate, (2-Cycle) months replace if required Engine breather 100 hrs Inspect hose...
  • Page 95 Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 96 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Remarks Miles Engine Mounts 100 hrs Inspect months Valve Clearance 100 hrs Inspect/Adjust (4-Cycle) months Injector Oil Filter 100 hrs Replace (2-Cycle) months Shift selector box (H/ 200 hrs Change lubricant every L/R) months two years...

  • Page 97: Lubrication Recommendations

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec Method Frequency* 1. Engine Oil Polaris Fill oil tank. See page 49. As needed, (2-Cycle) Injection when refuel- 2.Engine OIl Polaris Add to proper level on dip- Check level (4-Cycle) Premium stick. See page 105.
  • Page 98 MAINTENANCE AND LUBRICATION Lubrication Recommendations 4. Transmission (dipstick) Full Operating Range 4. Transmission (plug) 5. Front Gear Case Fill plug Fill plug 6. Front Prop Shaft (U-Joint) 7. Propshaft Yoke...
  • Page 99 MAINTENANCE AND LUBRICATION Lubrication Recommendations 10. Front Grease+ Locate grease fitting and Every 3 Drive Axle (U grease with grease gun. months or Joint) (AWD 50 hours Models) 11. Ball Joint Locate fitting on back side of Every 3 Grease struts and grease with grease months or gun.
  • Page 100 MAINTENANCE AND LUBRICATION Lubrication Recommendations 13. Counterbalance Dipstick 10. Axle Cardan Front Drive (AWD Models) 14. Steering Post Bushing 9. Demand 4 Hubs (4x4 only) Upper 9. 4 O’clock 12. Front A-Arm position Pivot Shaft 11. Ball Joint...
  • Page 101 Grease annually 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. + Grease every 500 miles, or before long periods of storage or after pressure washing, or after submerging in water.
  • Page 102 MAINTENANCE AND LUBRICATION Lubrication Recommendations 16. Swing Arm Bushings 15. Rear Axle Bearing INDEPENDENT REAR SUSPENSION 18. Lower Control 17. Upper Control 18. Lower Control 20. Rear Anti- 19. Rear Wheel Roll Bar Hub Bearing Carrier...

  • Page 103: Maintenance Record

    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.

  • Page 104: Cooling System

    Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. 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. NOTE: Polaris Premium 60/40 is already premixed and ready to use.

  • Page 105: Engine Cooling System

    MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair.
  • Page 106 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. NOTE: Polaris Premium 60/40 is already premixed and ready to use.

  • Page 107: Lubrication

    2-cycle oil. 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. The only oil recommended for this ATV is Polaris brand oil.
  • Page 108 Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for...
  • Page 109 MAINTENANCE AND LUBRICATION Lubrication Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″...
  • Page 110 MAINTENANCE AND LUBRICATION Lubrication Oil Pump Adjustment Procedure - 250 Engines 1. Before adjusting the oil Cable Adjuster pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. Locknut 2. Loosen throttle cable jam nut (A) and turn adjuster in or out until there is 1/16″...

  • Page 111: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Lubrication Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil reservoir and supply line have been completely run out of oil.
  • Page 112 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (4-Stroke models with an external oil tank) 1. Place vehicle on a level surface. 2. Clean area around drain plug which is found at the bottom of the oil tank or on the bottom of the engine. 3.
  • Page 113 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) (4-Stroke models with an external oil tank) 11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.
  • Page 114 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Magnum 325 2x4, Magnum 325 4x4, Trail Boss Oil and Filter Change 1. Place vehicle on a level surface. Crankcase Drain 2. Run engine two to three minutes until warm. Stop engine. 3.
  • Page 115 Oil Filter and Change (Cont.) Magnum 325 2x4, Magnum 325 4x4, Trail Boss 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place gear selector in neutral and set parking brake.
  • Page 116 O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 12. Remove dipstick and fill sump with 4.5 quarts (4.25L) of Polaris Premium 4 synthetic oil.
  • Page 117 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) Xpedition 325 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 15.
  • Page 118 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Xpedition 425 1. Place vehicle on a level surface. Oil Drain 2. Run engine two to three minutes until warm. Stop engine. 3. Clean area around drain plug. 4. Place a drain pan beneath engine crankcase and remove drain plug.
  • Page 119 Lubrication Oil Filter and Change (Cont.) Xpedition 425 12. Remove dipstick and fill sump with 5.5 quarts (5.2 l) of Polaris Premium 4 synthetic oil. 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.
  • Page 120 With the ATV on a level surface, remove fill plug (1) and check the lubricant level. Use the illustration and the chart below to determine the correct fluid level. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478). Model Oil Level “A”...
  • Page 121 Magnum drain plug). Catch and discard used oil properly. 4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93 kg-m). 5. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant until oil reaches the bottom of the filler hole.
  • Page 122 With the ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478).
  • Page 123 MAINTENANCE AND LUBRICATION Lubrication 2x4 Models To check the level: 1. Remove fill dipstick and wipe clean. 2. Reinstall dipstick completely, remove and check the level. Add the proper lubricant as required to bring level into operating range as shown. To change lubricant: 1.
  • Page 124 Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add 32 oz. (948 ml) Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to full mark on the fill plug/dipstick.

  • Page 125: Front Gearcase Lubrication

    MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug is located as shown. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. Type A - With the ATV on a level surface, remove fill plug and check the lubricant level.

  • Page 126: Rear Gearcase Lubrication

    MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a level surface, remove fill plug and visually inspect the lubricant level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2) approximately 1 5/8″ below the top of the fill hole.
  • Page 127 MAINTENANCE AND LUBRICATION Lubrication Counter Balance Lubrication - 400 Engines 1. Counter Balance Drain 2. Crankcase Drain 3. Recoil Drain 4. Starter Pinion Drain The counter balance oil should be checked semi-annually and oil should be added or changed as necessary.
  • Page 128 MAINTENANCE AND LUBRICATION Lubrication Procedure for Adding Oil 1. Remove seat and locate dipstick (1). 2. Remove dipstick. Oil level is shown on dipstick. 3. Add SAE 10W30 oil with a transmission fluid funnel until oil is at the proper level on the dipstick.

  • Page 129: Oil System

    MAINTENANCE AND LUBRICATION Lubrication Oil System The oil tank is located on the left side of the vehicle or on the engine, depending on the model. To check the oil: 1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds.

  • Page 130: Filter Systems

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

  • Page 131: Cleaning The Main Filter

    MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices. 1. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.
  • Page 132 MAINTENANCE AND LUBRICATION Filter Systems CAUTION Operation of your ATV without a breather filter can cause engine damage. Breather Filter and Hose 4-Cycle Engines With Dry Sump* 1. Remove the clamps and pull the filter (1) out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine.

  • Page 133: Adjustments

    MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable.
  • Page 134 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

  • Page 135: Rear Spring Adjustment

    Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer. Rear Spring Adjustment Rear Spring Adjustment...

  • Page 136: Handlebar Adjustment

    MAINTENANCE AND LUBRICATION Adjustments WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your...

  • Page 137: Front Brake

    Always fill the reservoir as indicated whenev- er the cover is loosened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid. S Check brake system for fluid leaks.

  • Page 138: Rear Brake

    Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have hydraulic brake systems. The hydraulic auxiliary brake system will not require adjustment.
  • Page 139 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes.
  • Page 140 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes.
  • Page 141 MAINTENANCE AND LUBRICATION Adjustments Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.
  • Page 142 MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.

  • Page 143: Wheel Installation

    Wheel Nut Torque Specifications Bolt Size Specification Front 3/8″ 20 Ft. Lbs. Rear 3/8″ 20 Ft. Lbs. Rear 1/2″ 50 Ft. Lbs. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris Dealer.

  • Page 144: Tire Inspection

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. Service work must be performed by your authorized Polaris dealer. Tire Inspection When replacing a tire always use original equipment size and type. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″...
  • Page 145 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION Never wash the chain with a high pressure washer or gasoline.
  • Page 146 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack Adjustment (Models with Concentric Drive) CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain.
  • Page 147 MAINTENANCE AND LUBRICATION Adjustments Adjustment Procedure 1. Loosen chain guide. 2. Loosen two eccentric locking bolts (2). 3. Loosen caliper mounting bracket bolts located under the axle. Rear Drive Chain Adjustment 4. Insert a pin punch through the sprocket hub and into the eccentric housing.

  • Page 148: Carburetor Adjustments

    NOTE: Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you. Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your machine.

  • Page 149: Lights

    MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement Headlight Lamp Replacement WARNING Keep your headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death. CAUTION Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers.

  • Page 150: High Beam Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement High Beam Headlight Adjustment The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a wall. 2.

  • Page 151: Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement Headlight Lamp Replacement (Trail Blazer) 1. Remove front cover and unplug the light harness. 2. Remove rubber cap from back of headlight to reveal retention screw. 3. Remove small phillips head screw, and carefully remove bulb from housing.
  • Page 152 MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement Headlight Lamp Replacement (Gen IV) Snap pins into tabs Position Slip O-Ring knob in over pin slot and secure in Adjustment Route indicator locking Knob Stop harness over tabs handlebar 1.
  • Page 153 MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement High Beam Headlight Adjustment (Gen IV) The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod.

  • Page 154: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement Headlight Housing Replacement 1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 2. Lift the pod lightly while depressing the tabs. 3.

  • Page 155: Taillight/Brakelight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights - - Adjustment - - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lense cover mounting screws. Remove the lense cover and gasket and set aside for reassembly.

  • Page 156: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 157: Water Service

    MAINTENANCE AND LUBRICATION Water Service CAUTION If your ATV becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected. If it is impossible to take it to a dealer before starting, follow the steps outlined below.

  • Page 158: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury or death. Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. Because of the increased fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
  • Page 159 MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels.

  • Page 160: Recoil Housing

    MAINTENANCE AND LUBRICATION Recoil Housing Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Using a wrench, remove the screw.

  • Page 161: Pvt

    Low Range Use May Reduce PVT Operating Temperatures 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.

  • Page 162: Pvt Drying

    MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed.

  • Page 163: Low Range

    MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs. High Range The following lists provide a guideline for when to use low range rather than high. Low Range: S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain (swamps, mountains, etc.) at low ground speeds High Range:...

  • Page 164: Battery

    MAINTENANCE AND LUBRICATION Battery WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

  • Page 165: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4.
  • Page 166 MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 167: Side Panel Removal

    MAINTENANCE AND LUBRICATION Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage...

  • Page 168: Cleaning And Storage

    Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement. Waxing Your ATV can be waxed with any non-abrasive automotive paste wax.

  • Page 169: Storage Tips

    High pressure washers may force water past seals. Drain the recoil housing. Stabilize Fuel - Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow instructions on the container for recommended amount. Carbon clean will also reduce the possibility of bacterial growth in the fuel system.
  • Page 170 MAINTENANCE AND LUBRICATION Cleaning and Storage * Fog The Engine - 2 Strokes - Polaris Fogging Oil (PN 2870791) follow directions on the can. 4-Strokes - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use a section of clear 1/4″...

  • Page 171: Maintenance And Lubrication

    4. Treat the fuel system with Polaris Carbon Clean. 5. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. to eliminate any fuel remaining in the carburetor, run the engine until it stops.

  • Page 172: Troubleshooting

    TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a pick- Shift transmission to low range during up or tall trailer when in high loading of the ATV to prevent belt burn- range.
  • Page 173 Clutch seals should be inspected for damage if repeated leaking oc- curs. Clutch malfunction. For inspection of clutch compo- nents, please contact your Polaris dealer. Poor engine perfor- Fouled plugs, foreign material in mance. gas tank, fuel lines, or carburetor.
  • Page 174 The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START...
  • Page 175 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER Spark Plug Engine No Fuel Fouled Overheated Turn Fuel Air Filter Clean Radiator Valve to “Res” Clogged screen and Radiator Core Fuel Vent Line (liquid cooled Reverse Speed Kinked or models) Limiter Plugged Malfunction Clean Engine Electronic Water in Fuel...

  • Page 176: Warranty

    This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.
  • Page 177 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 178 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 179 INDEX Adjustments ....133-148 Handlebar Adjustment ... . . Air Cleaner ....127-128 Headlight Adjustment .
  • Page 180 INDEX Toe Alignment ....130-131 Troubleshooting ....169-172 Torque Specifications ....Turning Around On a Hill .

Table of Contents