Polaris PTV 4x4 Series 10 Owner's Manual
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Polaris PTV 4x4 Series 10 Owner's Manual

Polaris PTV 4x4 Series 10 Owner's Manual

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  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 4 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

  • Page 5: Welcome

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

  • Page 6: Identification Numbers

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

  • Page 7: Table Of Contents

    ....... . POLARIS RECOMMENDED PRODUCTS ...

  • Page 8: Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris PTV 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 9 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. 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 10 S Never operate the PTV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you. S Never allow anyone under 16 years of age to operate this vehicle.
  • Page 11 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the vehicle inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the vehicle or for your abilities.
  • Page 12 Allow a greater distance for braking. S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call the Consum- er Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.

  • Page 13: Equipment Modifications

    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 PTV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 14 PTV 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 PTV.
  • Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the vehicle, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN PTV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the vehicle and could result in loss of control, accident and/or injury.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN The vehicle could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the vehicle on any public street, road or highway, including dirt and gravel roads.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating this vehicle without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the vehicle 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 this vehicle could result in an accident causing severe injury or death.
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle before each use to make sure it’s in safe operating condition.
  • Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the vehicle on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 24 SAFETY Operator Safety 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.
  • Page 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 26 SAFETY Operator Safety 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. A special technique is required when braking while traveling downhill.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 29 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 30 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the vehicle 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 vehicle through deep or fast-flowing water.
  • Page 31 Never modify the vehicle 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 vehicle and should be installed and used according to approved instructions. See...
  • Page 32 SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the vehicle or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle.
  • Page 33 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
  • Page 34 Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 35 SAFETY Safety Decals and Locations WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16. WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
  • Page 36 SAFETY Safety Decals and Locations WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs 7070021 WARNING Moving parts hazard under belt-clutch guard.
  • Page 37 SAFETY Safety Decals and Locations MANUFACTURED WARNING BY: POLARIS IND OVERRIDE SWITCH Pushing reverse DATE: override button may cause Reverse Speed is VIN: sudden increases limited. in power and trac- THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND tion if too much Reverse override is IS NOT INTENDED FOR USE ON PUBLIC ROADS.
  • Page 38 SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well ventilated area with the engine stopped. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 39 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. Riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 40: Controls

    CONTROLS Electrical Switches and Indicators WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.
  • Page 41 CONTROLS Electrical Switches and Indicators With the engine running, verify the function of all indicator lights each time the vehicle is used. 1 Transmission Neutral Indicator (Green) 2 Transmission Reverse Indicator (Yellow) 3 High Temp Indicator (Red) The high temp indicator will light only if the engine overheats. 4 High Beam Indicator (Blue) The high beam indicator is located on the left-hand switch.
  • Page 42 This vehicle is equipped with a 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 43 CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.

  • Page 44: Master Cylinder

    CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full.
  • Page 45 The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Your Polaris PTV has an auxiliary brake (1) for added safety. It’s located on the...

  • Page 46: Parking Brake

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

  • Page 47: Fuel Tank

    CONTROLS Engine Fuel and Oil System Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel of the vehicle.

  • Page 48: Belt Life

    CONTROLS Gear Selector Operation The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
  • Page 49 (1) will allow vehicle operation until repairs can be made. The recoil starter is located next to the right-hand footrest. 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 operation.

  • Page 50: Features

    FEATURES Electronic Speedometer CAUTION High water pressure may force water into the speedometer and cause damage to the electronic components. Do not wash the electronic speedometer with a high pressure washer. Wash the unit by hand or with a garden hose. The electronic speedometer senses vehicle speed from the right front wheel.
  • Page 51 FEATURES Electronic Speedometer Access Sub-menu Features There are two methods for accessing the sub menu. 1. Press and hold the button and turn the power on, or 2. Press and hold the button for eight seconds. When the display shows POLArS, release the button. To display each mode, press the button once to scroll through the four available functions.
  • Page 52 FEATURES Electronic Speedometer Check When Service is Due by Hours Using the 50-hour service setting as an example, the speedometer will take the 50-hour setting and add it to the value of the hour meter. This will be the value displayed when the operator checks when service is due for the vehicle.

  • Page 53: Operation

    OPERATION Vehicle Break-in Period The break-in period for your new Polaris PTV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 54 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not performed before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper operating condition before each use.

  • Page 55: Starting The Engine

    OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface.

  • Page 56: Starting A Warm Engine

    Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.
  • Page 57 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 58: Hauling Cargo

    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN CARRYING CARGO.
  • Page 59 OPERATION Hauling Cargo Your vehicle has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities specified in your owner’s manual and on safety decals. Maximum Capacities Front Rack Rear Rack...

  • Page 60: Turning The Vehicle

    Turning the Vehicle Practice making turns at slow speeds. The Polaris PTV is 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 61: 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 62: Driving Uphill

    OPERATION Driving Safely Driving Uphill 25_ Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 63 OPERATION Driving Safely Driving on a Hillside 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.

  • Page 64: Driving Downhill

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary rear brake pedal in the event loss of normal service brakes occurs.
  • Page 65 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 66: Driving Through Water

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

  • Page 67: Driving Over Obstacles

    OPERATION 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 68: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. 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. WARNING Failure to use caution when operating in reverse can result in serious injury or death.

  • Page 69: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.
  • Page 70 - NOTES -...

  • Page 71: Noise Emission Control System Regulation

    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 72: Maintenance And Lubrication

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

  • Page 73: Periodic Maintenance Schedule

    Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles...
  • Page 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles Air filter/Main ele-...
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles Oil Filter 100 hrs./ 6 months Replace with oil change " 1000 mi. Engine breather 100 hrs. 6 months Inspect hose Carburetor float 50 hrs. 6 months Drain bowl periodically and bowl prior to storage Throttle Cable/ETC...
  • Page 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles Radiator 100 hrs.
  • Page 77 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person 10 hrs. 20 hrs. 50 hrs. 100 hrs.

  • Page 78: Lubrication Recommendations

    Maintenance Chart Key More often under severe use, such as wet or dusty conditions " Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2 Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
  • Page 79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Method Frequency* (5) Hubs Premium Hub Remove set screw in hubs. Annually or at 100 Lube Rotate wheels to 4 O’clock hrs. position. If lubricant is not visible add more. Reinstall set screw. (6) Ball Joint Locate fitting on back side of Every 3 months or...
  • Page 80 49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40.
  • Page 81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles (1600 km), or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles (320 km), or one month, whichever comes first.
  • Page 82 Season synthetic oil or API certified SH oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40. 12. Remove the dipstick (2) and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil (see page 115). Reinstall the dipstick.

  • Page 83: Transmission Lubrication

    With the vehicle on a level surface, remove the fill plug and check the lubricant level. The level should be 1 5/8″ from the top of the fill hole (A). Add Polaris Premium Synthetic Gearcase Lubricant if necessary. See page 115 for part numbers for Polaris-recommended products.
  • Page 84 Discard the used oil properly. 5. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). 6. Add Polaris Premium Synthetic Gearcase Lubricant (see page 115) until oil reaches the bottom of the filler hole. 7. Reinstall the fill plug and check for leaks.
  • Page 85 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Lubrication 1. Position the vehicle on a level surface. Remove the fill plug (1) and visually inspect the lubricant level. Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8″...
  • Page 86 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use (see page 115). Do not dilute with water. Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

  • Page 87: Radiator Coolant Level

    NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 88 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service Polaris recommends that the air filter be replaced annually. When riding in extremely dusty conditions, replace it more often. 1. Remove the seat. 2. Release the clips securing the air box lid and remove the lid.
  • Page 89 MAINTENANCE AND LUBRICATION Filter Systems CAUTION Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter. Breather Filter and Hose 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 90 (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service.

  • Page 91: Steering Inspection

    Camber and Caster The camber and caster are non-adjustable. 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.
  • Page 92 MAINTENANCE AND LUBRICATION Adjustments WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious injury or death. Perform the handlebar adjustment exactly as outlined. Handlebar Adjustment Your PTV has handlebars that can be adjusted for a personal fit.

  • Page 93: Front Brakes

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (see page 115). 2. Check the brake system for fluid leaks.
  • Page 94 MAINTENANCE AND LUBRICATION Adjustments Brake Adjustments Rear Brake The transmission brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The transmission brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.
  • Page 95 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Start the engine and allow it to warm up for approximately five minutes.
  • Page 96 NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. NOTE: Pilot screws are sealed with metal plugs and are serviceable...
  • Page 97 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2 2. Grasp the rear of the side panel near the rear cab.

  • Page 98: Tire Tread Depth

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

  • Page 99: Wheel Installation

    3. Lower the vehicle to the ground. 4. Torque the wheel nuts to 20 ft. lbs. (27 Nm). Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

  • Page 100: Spark Plugs

    S Spark plug torque is 14 ft. lbs. (19 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 101: Spark Arrestor

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

  • Page 102: Vehicle Immersion

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

  • Page 103: Pvt System

    Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 104 MAINTENANCE AND LUBRICATION Recoil Housing Water will enter the recoil housing if the starter handle is disengaged from the rope or if the handle is not securely seated when operating in wet conditions. Drain the recoil housing any time the vehicle has been operated in very wet conditions and also before storage.

  • Page 105: Battery Removal

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

  • Page 106: Battery Storage

    MAINTENANCE AND LUBRICATION Battery Battery Installation and Connections 1. Set the battery in the battery holder. 2. Install the battery vent tube. NOTE: It must be free of 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 107: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently.
  • Page 108 MAINTENANCE AND LUBRICATION Lights High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight approximately 25 ft.
  • Page 109 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. Remove the screw in the back of the headlight pod.
  • Page 110 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (1). Remove the lens cover (2) and gasket and set aside for reassembly.

  • Page 111: Cleaning And Storage

    Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer (see page 115). Follow the instructions on the container for recommended amount. Carbon clean will also reduce the possibility of bacterial growth in the fuel system.

  • Page 112: Battery Maintenance

    Charge the battery at 1.4 amps or less until specific gravity of each cell is 1.265 or greater. Store the battery in a cool, dry, place. Charge can be maintained easily by using Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
  • Page 113 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting 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. 4.

  • Page 114: Specifications

    SPECIFICATIONS Carburetion Type ......BST 34 Mikuni Main Jet ......157.5 Pilot Jet .

  • Page 115: Drive Train

    (incl. machine, driver and cargo) ..1150 lbs. (522 kg) Polaris Industries Inc. reserves the right to make changes in design and specifi- cations and/or to make additions or improvements to its products without notice.
  • Page 116 SPECIFICATIONS Jetting Chart Altitude AMBIENT Below 40° F +40°F and above TEMPERATURE (Below 5° C) (+5°C and above) Meters 0-1800 162.5 157.5 (Feet) (0-6000) Over 1800 (Over 6000) Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix/Spring Weight Spring Spring Setting Meters 0-1800...

  • Page 117: Polaris Recommended Products

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

  • Page 118: 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 Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections...
  • Page 119 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...

  • Page 120: Engine Overheating

    Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...
  • Page 121 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact your dealer.

  • Page 122: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE.
  • Page 123 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 124: Engine Oil

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

  • Page 125: Index

    INDEX Accessories ..... . FEATURES ....48-50 Adjustments .
  • Page 126 38-39 Parking on an Incline ....POLARIS RECOMMENDED PRODUCTS ....TABLE OF CONTENTS .

Table of Contents