• RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
Troubleshooting ..... . . 133 Polaris Products..... . . 137 Specifications .
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.
ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
• make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. SAFETY General Warning...
SAFETY Safety Decals and Locations Passenger Safety Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.
Safety Decals and Locations Rack Warning Rack Warning 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. (41 kg) Rear 180 lbs. (82 kg) Clutch Cover Warning WARNING NO STEP...
Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A...
Rider Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly...
Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols 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 injury.
• Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse •...
Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. • Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. • Never operate on hills too steep for the ATV or for your abilities.
Rider Safety • Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side.
Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342- 3764.
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. WARNING...
Rider Safety POTENTIAL HAZARD Operating with more than one passenger. WHAT CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control, which can result in severe injury or death. HOW TO AVOID THE HAZARD Never operate the 2-up ATV with more than one passenger.
Rider Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
Rider Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
Rider Safety POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving. POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.
Rider Safety POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.
SAFETY Rider Safety 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.
Rider Safety POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees.
SAFETY Rider Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning on hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual.
SAFETY Rider Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
Rider Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
SAFETY Rider Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
SAFETY Rider Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
Rider Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and physical skills.
FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch 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. Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.
Switches Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns.
The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the...
Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.
If the fluid level is low add DOT 4 brake fluid only. See page 137 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level.
Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Place the transmission in PARK.
Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Since this is a rear brake only, it will not be as effective as the all-wheel NOTE: single lever system.
Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.
NOTE: If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. To remove the seat, pull the latch loop at the rear of the seat. Pull the seat upward to remove it from the vehicle.
All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off.
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:...
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. The instrument cluster mea- sures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approxi- mately 7-9 mph.
If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 36. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV.
Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil.
Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.
Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 55 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
Instrument Cluster Rider Information Center Downloading Codes Blink Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage...
OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Break-In Period The break-in period for your new Polaris ATV is 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 proce- dures for a proper break-in.
Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. WARNING...
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. Never carry cargo on the rear rack when operating the ATV in the 2-up mode with a passenger.
ATV warranty. Never install a hitch longer than 6 3/4" (17 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris-approved (or equivalent) accessories designed for ATV use. Maximum Towing Capacities Do not exceed maximum towing capacities.
OPERATION Driving Procedures 1. Wear protective riding gear. See page 10. 2. Perform the pre-ride inspection. See page 58. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.
Turning the Vehicle Both rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.
OPERATION Driving with a Passenger 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, includ- ing an approved helmet with a rigid chin guard.
Driving with a Passenger 10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a pas- senger to fall from the vehicle. 11. Do not cross a hillside with a passenger on board. See page 68. 12.
OPERATION 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. Engage 4X4 before wheels begin to lose trac- tion.
Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 47. 2. Drive straight uphill. 3. Avoid steep hills (15° maximum). 4. Keep both feet on the footrests. 5.
OPERATION Driving on a Sidehill (Sidehilling) Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Do not cross a hillside with a passenger on board. Follow proper procedures as outlined in the owner's manual.
Driving Downhill Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 47. 3. Leave the transmission in forward and shut off the engine. 4.
OPERATION Driving Through Water Maximum Depth Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3.
Driving Through Water After running the vehicle in water, it's critical to have it serviced as out- lined in the maintenance chart. See page 79. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings.
OPERATION Driving Over Obstacles 1. 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 hang- ing branches. 2. Avoid operating over large obstacles such as rocks and fallen trees when possible.
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
OPERATION Driving in Reverse Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly. Do not use the override switch unless additional power is required for vehicle movement.
6. Never open the throttle suddenly. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Apply just enough throttle to maintain a desired speed.
CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 148.
E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
Periodic Maintenance Chart Item Hours Calendar Air filter, main element Recoil housing (if applicable) Brake pad wear Battery Rear gearcase oil (if equipped) Transmission oil Demand drive fluid Engine breather filter (if equipped) General lubrication Shift linkage Steering Front suspension Rear suspension Throttle Cable/ ETC Switch...
Fuel filter Spark arrestor Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect;...
Item Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Brake Fluid DOT 4 Only Transmission Oil Polaris AGL Syn- thetic Gearcase Lube Demand Drive Demand Drive LT Fluid Premium Fluid (Front Gearcase) ADC Fluid Polaris ADC Fluid...
Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.
Engine Oil Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture col- lecting in the crankcase.
MAINTENANCE Engine Oil Oil Level (800 EFI) Access the oil dipstick and fill tube from the left side of the ATV. 1. Position the vehicle on a level surface. 2. Lift the lever lock to remove the dipstick. Wipe it dry with a clean cloth.
Engine Oil Oil and Filter Change (500 EFI) Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. 1.
MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine.
Engine Oil Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2"...
MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Always change the oil filter whenever changing oil.
Oil and Filter Change (800 EFI) 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counter- clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
Periodic Maintenance Chart beginning on page 79. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 137 for the part numbers of Polaris products.
Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of components. See page 137 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads.
Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of Polaris ADC Fluid. See page 137 for the part numbers of Polaris products. NOTE: Do not use brake fluid.
Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door. 2. View the fluid level in the reservoir. If the level is below the minimum mark, remove the cap and add the recommended fluid. 3.
Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 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. Do not dilute with water. See page 137 for the part numbers of Polaris products.
Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair.
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.
1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. MAINTENANCE WARNING Stand...
MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.
Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK.
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in PARK. 2. Lock the parking brake.
Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre- filter in soapy water, then rinse and let dry.
MAINTENANCE Breather Filter/Hose (500 EFI) The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 100. 2. Remove the hose clamps from the fil- ter and pull the filter out of the hoses.
Fuse Replacement Fuse If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. NOTE: Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door.
MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2.
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4.
Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 138 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification.
Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white.
Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. 1. If it's impossible to take your ATV to a dealer before starting it, fol- low the steps outlined below.
Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.
• 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.
MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.
MAINTENANCE PVT System When To Use Low Range and High Range Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) PVT Drying There may be some instances when water is accidently ingested into the PVT system.
Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.
MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.
Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 121 before installing the battery.
Power plug leads may need to be bent down so that the battery cover can be installed. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 118. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action specified on top of battery) None, check at 3...
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.
• Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
Make any necessary repairs and clean the vehicle as recommended. See page 123. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...
6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline. MAINTENANCE...
Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your...
Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.
The camber and caster are non-adjust- able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer. Adjuster...
Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.
ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar.
Dry out the PVT. See page 116. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...
Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...
Chain Lube, Aerosol (6.25 oz./185 ml) 2872348 Chain Lube, Aerosol (16 oz./473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender POLARIS PRODUCTS Engine Lubricant Coolant Additives / Miscellaneous Charger...
10.2:1 Electronic Fuel Injection Electronic Ignition 10 +/- 1 BTDC @ idle NGK BKR6E .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Dry Sump Automatic PVT (Polaris Variable Transmis- sion) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.75" (22 cm) travel...
Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching (EBS Models) Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) NOTE: *EBS models require no helix/spring adjustment...
500 Watts @3000 RPM 10:1 Electronic Fuel Injection Electronic Ignition Variable - ECU controlled RC7YC .035 in. (0.9 mm) Pressurized Wet Sump Automatic PVT (Polaris Variable Transmis- sion) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.75" (22 cm) travel...
Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching (EBS Models) Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) NOTE: *EBS models require no helix/spring adjustment...
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
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. This warranty also does not cover any ATV that...
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.
How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...