Polaris UTV Series 10 2x4 Owner's Manual
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Polaris UTV Series 10 2x4 Owner's Manual

Polaris UTV Series 10 2x4 Owner's Manual

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Summary of Contents for Polaris UTV Series 10 2x4

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 4 - NOTES -...
  • Page 5 Your Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified Master Service Dealer (MSD) Technician. Your Polaris UTV dealer knows your vehicle best and is interested in your complete satisfaction.
  • Page 6 THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions.
  • Page 7 Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. n Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. n Never operate this vehicle on hills too steep for the vehicle or for your abilities.
  • Page 8 Always turn off the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 54 for refueling instructions. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.
  • Page 9 We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris UTV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 10 - NOTES -...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS Vehicle Identification Numbers ... . . Safety ........Features and Controls .
  • Page 12 - NOTES -...

  • Page 13: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identifaction number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.

  • Page 14: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your UTV. 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 UTV or in this manual, alerts you to the potential for personal injury.
  • Page 15 We strongly recommend that the operator check all safety components before each ride. Polaris UTVs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Lock the parking brake after when fully stopped.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.
  • Page 19 SAFETY Operator Safety WARNING Safe operation of this vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control, which could result in serious injury or death. WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds...
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your UTV before each use to make sure it’s in safe operating condition.
  • Page 21 WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris UTV. Even though a child may be within the age group for which some...
  • Page 22 Never modify this vehicle through improper installation or use of accessories. All parts and accessories should be genuine Polaris Sales Inc. or equivalent components designed for use on the vehicle, and they should be installed and used according to instructions.

  • Page 23: Driving On Slippery Surfaces

    SAFETY Operator Safety Driving On Slippery Surfaces WARNING Extra caution is required when operating on slippery surfaces. Loss of tire traction and vehicle control can result in an accident, including an overturn. Never apply brakes during a skid. Complete loss of control can result.
  • Page 24 SAFETY Operator Safety Operating on Hills WARNING Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at high speed.
  • Page 25 SAFETY Operator Safety Operating on Hills WARNING 15_ Maximum Braking and handling are greatly affected when operating in hilly terrain. Loss of vehicle control or overturning of the vehicle could occur. Avoid climbing steep hills (15_ maximum). Use extreme care when operating your vehicle in hilly terrain. WARNING Improperly crossing hills or turning on hills could cause loss of control or vehicle overturn.
  • Page 26 Never try to cross a deep or fast-flowing stream. The large tires can cause the vehicle to float, resulting in loss of control. Your Polaris UTV can operate through water up to depths reaching the floorboards. Before fording streams: 1. Always determine water depths and current.
  • Page 27 SAFETY Operator Safety Trail Obstacles Stay alert! Look ahead and learn to read the trail as you drive. Stay on the righthand side of the trail and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous.
  • Page 28 SAFETY Operator Safety Operating in Reverse 1. When backing up, always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6.

  • Page 29: Parking On An Incline

    SAFETY Operator Safety Parking On An Incline 1. Place the transmission in gear. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the downhill side. WARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle.

  • Page 30: Carrying Loads

    SAFETY Operator Safety Carrying Loads The UTV has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Maximum Capacities Cargo Box (Level Ground) UTV 2X4 1350 lbs.

  • Page 31: Dumping The Cargo Box

    SAFETY Operator Safety Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Press and hold the cargo box dump switch in the upward position to dump.

  • Page 32: Towing Loads

    SAFETY Operator Safety Towing Loads Maximum Towing Capacities (Level Ground) Total Towed Total Towed Total Hitch Towing Load Weight Load Weight Vertical Speed (level ground) (15° grade) Weight 1400 lbs. 800 lbs. 150 lbs 10 mph (636 kg) (364 kg) (68.1 kg) (16 kph) or less...
  • Page 33 SAFETY Operator Safety Parking the UTV 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake to help prevent the vehicle from rolling. WARNING Always apply the parking brake before leaving the vehicle. If the vehicle should roll, it may cause damage or injury.
  • Page 34 SAFETY Safety Decals and Locations WARNING S VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection. S ALWAYS WEAR YOUR SEAT BELT for maximum protection. 7079425 Location 1 WARNING S Moving parts hazard under belt-clutch guard.
  • Page 35 SAFETY Safety Decals and Locations ATTENTION D Specific D Operation of this vehicle without carburetor jetting and the filter element will severely adjustments are required depending on damage the engine. temperature and altitude. See your D Clean air filter often, more Owner’s Manual.
  • Page 36 SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS...
  • Page 37 READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS...

  • Page 38: Features And Controls

    FEATURES AND CONTROLS Features 1. Cab Frame 2. Cab Frame Hand Hold 3. Dashboard 4. Steering Wheel 5. Seat 6. Cargo Box 7. Seat Belts 8. Fuel Tank Cap / Fuel Gauge 9. Battery (under seat)
  • Page 39 FEATURES AND CONTROLS Features 10. Headlights 11. Radiator 12. Front Bumper/Brush Guard 13. Hood Hold Down Strap...
  • Page 40 FEATURES AND CONTROLS Features 14. Oil Tank 15. Battery (Under Seat) 16. Tail Lights 17. Tail Gate 18. Tailgate Latch Release 19. Airbox (under cargo box) 20. Muffler (Spark Arrester) 21. Rear Caliper 22. Trailer Hitch Receiver 23. Engine Oil Plug...

  • Page 41: Trailer Hitch Bracket

    FEATURES AND CONTROLS Features Auxiliary Lighting/Electrical Accessory Terminals The 12-volt receptacle (1) has spade connections on the back that may be used to power an auxiliary light or other optional lights or accessories. To locate these connections, lift the hood and look behind the dash board.
  • Page 42 FEATURES AND CONTROLS Features Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
  • Page 43 FEATURES AND CONTROLS Controls 1. Choke Knob 2. Ignition Switch 3. Hour Meter 4. Indicator Lights 5. 12V Accessory Plug 6. Fog/High Beam Light Switch 7. AWD (All Wheel Drive) Switch (if equipped) 8. Shift Lever 9. Differential Lock Lever 10.
  • Page 44 FEATURES AND CONTROLS Controls Transmission Gear Selector Operation The transmission gear selector (1) is located on the console to the right of the steering wheel. It has four positions (2): high, low, neutral and reverse. NOTE: Low is the primary driving range for this vehicle.

  • Page 45: Brake Pedal

    FEATURES AND CONTROLS Controls Brake Pedal The brake pedal (1) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal (2) is the right pedal on the floor board. Push the pedal down to increase engine speed.
  • Page 46 FEATURES AND CONTROLS Controls Ignition Switch (1) The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Engine off. All electrical circuits are off except Acc. 12V. Electrical circuits are on.
  • Page 47 Controls All Wheel Drive (AWD) Your Polaris UTV 4X4 is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the dash. When the switch is off, the UTV is in two-wheel drive at all times.

  • Page 48: Parking Brake Lever

    FEATURES AND CONTROLS Controls Parking Brake Lever The parking brake (1) is located below the dash in the center of the vehicle. It will help prevent the vehicle from rolling while parked. To apply the parking brake, push down on the pedal with your foot.

  • Page 49: Operation

    OPERATION Before You Ride Daily Pre-operation Inspection WARNING If a proper inspection is not performed, serious injury or death can result. Always inspect your UTV before operating. Inspect your vehicle before each operation to ensure it’s in proper working order. Before operating your vehicle, inspect all operating controls and parts.
  • Page 50 OPERATION Vehicle Break-In Period The break-in period for your new Polaris UTV is the first twenty 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 51: Starting The Engine

    OPERATION Starting the Engine WARNING Do not start or operate this vehicle with sticking or improperly operating throttle pedal. Doing so could cause an accident leading to severe injury or death. Always contact your dealer for service repairs if throttle problems arise.
  • Page 52 OPERATION Starting the Engine CAUTION Improper engine warm-up may cause engine damage. Follow recommended engine starting procedures. WARNING Carbon monoxide exhaust gas is poisonous! Always start the vehicle outdoors. Never run the engine in an enclosed area. WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm.
  • Page 53 OPERATION Starting the Engine Procedure for Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface.
  • Page 54 5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission (PVT) shifting is automatic. 6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

  • Page 55: Stopping The Engine

    OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Put the gear shift lever into neutral. 3. Apply the parking brake to help prevent the vehicle from rolling. WARNING Always apply the parking brake before leaving the vehicle. Movement may result in damage or personal injury.
  • Page 56 Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol is not covered by Polaris Warranty. n Never use gasohol with an octane rating lower than the minimum octane rating specified for this product. Always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

  • Page 57: Noise Emission

    NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or...

  • Page 58: Maintenance And Lubrication

    CAUTION Due to the nature of adjustments indicated by a , it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair. Item Frequency Remarks...

  • Page 59: Periodic Maintenance Schedule

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Frequency Remarks Tail lamp Daily Check daily; apply Polaris dielectric grease to socket when replaced Air Filter - Main Ele- Weekly Inspect; replace if necessary " ment " Transmission Oil 25 hrs Check level; change oil annually...
  • Page 60 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Frequency Remarks J Steering 50 hrs Inspect; lubricate " Front Suspension 50 hrs Inspect; lubricate, tighten fasteners " Rear Suspension 50 hrs Inspect, tighten fasteners Coolant strength/ 100 hrs Inspect strength seasonally; pres- pressure test system sure test system annually Engine Mounts...

  • Page 61: Lubrication Recommendations

    Shaft * 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 50 hours, or after submerging in water or before long periods of storage or after pressure washing.
  • Page 62 MAINTENANCE AND LUBRICATION Lubrication Recommendations...
  • Page 63 If using non-recommended engine oil is determined to have caused engine damage, repair and/or replacement will not be covered under Polaris warranty. We recommend the use of Polaris Premium 4 All Season Synthetic Oil or API certified “SH” oil. Never mix oil brands. WARNING...
  • Page 64 MAINTENANCE AND LUBRICATION Oil System Oil and Filter Change Maintain the engine oil at the proper level to ensure a properly functioning engine, and change the oil and oil filter in accordance with the Periodic Maintenance Schedule. Dirt and metal particles collect in the oil, and oil loses its lubricative quality if used too long.
  • Page 65 MAINTENANCE AND LUBRICATION Oil System Oil and Filter Change (cont.) 8. Disconnect the lower oil delivery hose. Remove the fitting (1) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach the oil line. Torque the banjo fitting (2) to 14-17 ft.

  • Page 66: Fuel Filter

    Oil System Oil and Filter Change (cont.) 14. Reinstall drain plug. 15. Remove dipstick and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

  • Page 67: Transmission Oil

    3. Check the lubricant level. Lubricant should be kept at the bottom of the fill plug threads. NOTE: We recommend the use of Polaris Premium Synthetic Gearcase Lubricant for optimum performance. CAUTION Do not allow dirt or foreign materials to enter the transmission case.

  • Page 68: Front Gearcase

    Failure to properly maintain this important area can result in premature wear or possible failure of the front grease components. NOTE: We recommend the use of Polaris Premium Hub Oil for optimum performance. The front gearcase fill plug (1) is located on the right side of the front gearcase.

  • Page 69: Cooling System

    MAINTENANCE AND LUBRICATION Cooling System Operation The overflow bottle (1) is located in front of the right front tire of the machine. The coolant level must be maintained between the minimum and maximum marks on the overflow bottle. The engine coolant level is controlled or maintained by the recovery system.
  • Page 70 Reinstall the cap. NOTE: Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 71 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. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations...
  • Page 72 MAINTENANCE AND LUBRICATION Cooling System Radiator and Cooling Fan Check and clean the screen and radiator fins for obstructions caused by insects or mud as outlined in the Periodic Maintenance Schedule. CAUTION Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness.

  • Page 73: Pvt Drying

    Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your dealer! This PVT system is intended for use on Polaris products only. The PVT housing must be securely in place during operation. Failure to comply with this warning can result in severe injury or death.

  • Page 74: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle 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’s impossible to take your UTV to a dealer before starting it, follow the steps outlined below.
  • Page 75 MAINTENANCE AND LUBRICATION Air Filter Service We recommended that the air filter be replaced annually. When operating in extremely dusty conditions, replacement will be required more often. 1. Lift the box. 2. Remove the cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.
  • Page 76 MAINTENANCE AND LUBRICATION Breather Filter and Hoses WARNING Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns. 1. Lift the box and locate the airbox (1). 2.

  • Page 77: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK BKR5E spark plugs. S Proper electrode gap is .036″ (.90 mm). S Spark plug torque is 14 ft. lbs.(19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 78 MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement WARNING The exhaust system or engine can cause serious burns. Always wait for the engine to cool before removing spark plugs. 1. Remove the seat to access the engine compartment. 2. Remove the spark plug cap. 3.

  • Page 79: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows. Use the following procedure. WARNING Do not perform this operation immediately after the engine has been run. Exhaust system temperatures can reach 1000° F. Because of the increased fire hazard, make sure there are no combustible materials in the area when purging the spark arrestor.
  • Page 80 MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3.
  • Page 81 MAINTENANCE AND LUBRICATION Throttle Pedal Throttle Freeplay If the throttle pedal (1) has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be...
  • Page 82 MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Schedule, or whenever the idle speed is changed. Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure.
  • Page 83 MAINTENANCE AND LUBRICATION Brakes Front and Rear Brake Inspection The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 43. Routine inspections are recommended to keep the brake system in good operating condition.
  • Page 84 Do not operate the vehicle under these conditions. Have the brake system serviced by an authorized Polaris dealer immediately. Brake Light Inspection When the brake pedal is depressed, the console brake light comes on.
  • Page 85 MAINTENANCE AND LUBRICATION Brakes Parking Brake Inspection 1. Slowly push the parking brake down with your foot. 2. After 8 to 12 clicks of lever travel, check the vehicle for movement. The vehicle should not roll while parked. If the vehicle moves, adjustment is necessary Parking Brake Adjustment...

  • Page 86: Steering Wheel Inspection

    3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play. 4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized Polaris dealer. Rear Spring Adjustment The rear shock absorber springs...
  • Page 87 3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The UTV seat belt is adjustable and should be adjusted for both the operator and passenger before driving.

  • Page 88: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control, and an accident. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. CAUTION Always maintain proper tire pressure. Improper tire inflation may affect vehicle maneuverability.

  • Page 89: Wheel Removal

    MAINTENANCE AND LUBRICATION Wheels Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the frame.

  • Page 90: Headlight Beam Adjustment

    MAINTENANCE AND LUBRICATION Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a 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 91 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the dash panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the dash panel.
  • Page 92 Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your Polaris dealer for free replacement. If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels.
  • Page 93 MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder.

  • Page 94: Removal From Storage

    4. Check all the points listed in the Daily Pre-Operation Inspection section beginning on page 47. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate as outlined in the Periodic Maintenance Schedule. WARNING Do not run the engine in a closed area.

  • Page 95: Battery Connections

    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid CAUTION Whenever removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often.

  • Page 96: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

  • Page 97: Battery Installation

    MAINTENANCE AND LUBRICATION Battery Battery Installation CAUTION If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the UTV. WARNING To avoid the possibility of explosion, always connect battery cables in the order specified.

  • Page 98: Specifications

    SPECIFICATIONS UTV 2 X 4 UTV 4 X 4 Gross Vehicle Weight 2500 lbs. 2700 lbs. Fuel Capacity 8.0 Gallons 8.0 Gallons Towing Capacity 1400 lbs. 1500 lbs. Maximum Cargo Box Load 850 lbs. 1000 lbs. Overall Length 113 in. 113 in.
  • Page 99 SPECIFICATIONS UTV 2 X 4 UTV 4 X 4 Lubrication System Dry Sump Dry Sump Engine Oil 0W/40 0W/40 Driving System Type Shift Type Single Lever on dash Single Lever on dash Gear Reduction - Low 8.6:1 8.6:1 Gear Reduction - Reverse 5.9:1 5.9:1 Gear Reduction - High...

  • Page 100: Troubleshooting

    TROUBLESHOOTING ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plug Plugged fuel No Spark to Drain System line or fuel Spark Plug filter Contact Your Dealer ENGINE STOPS OR LOSES POWER Overuse of Spark Plug Engine No Fuel Choke Fouled...
  • Page 101 The following information is provided to help you identify probable causes for questions you may have about the operation of your vehicle. See your Polaris dealer with any additional questions you may have. Disengaging AWD System Under certain conditions, it may be possible for the AWD system to remain engaged.

  • Page 102: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
  • Page 103 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 104 INDEX Accessory Plug, 12V ....MAINTENANCE/LUBRICATION 56-95 Air Box ......Maintenance Schedule .

This manual is also suitable for:

Utv series 10 4x4

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