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Polaris Universal ATV 2000 Owner's Safety And Maintenance Manual

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2000
Universal
ATV
Owner's Safety
and
Maintenance Manual
Read this manual carefully. It contains
important safety information. This is an
Part No. 9915299 Rev 05
adult vehicle only. Operation is prohibited
PRINTED IN THE U.S.A.
for those under 16 years of age.

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Summary of Contents for Polaris Universal ATV 2000

  • Page 1 2000 Universal Owner’s Safety Maintenance Manual Read this manual carefully. It contains important safety information. This is an Part No. 9915299 Rev 05 adult vehicle only. Operation is prohibited PRINTED IN THE U.S.A. for those under 16 years of age.
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm.
  • Page 3 ATV are thoroughly inspected at various intervals. All information in this manual is based upon the latest product data and specifica- tions available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or ex- planations.
  • Page 4 Do not turn at excessive speed. • Always have the ATV checked by an authorized Polaris dealer if it has been in- volved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities. Practice...
  • Page 5 Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
  • Page 6 Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle;...
  • Page 7 (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its prod- ucts.

  • Page 8: Table Of Contents

    CONTENTS UNDERSTANDING WARNINGS ......SAFETY WARNING AND OPERATION DECALS ... 3-13 DAILY PRE-RIDE INSPECTION .

  • Page 9: Understanding Warnings

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

  • Page 10: Understanding Warnings

    UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

  • Page 11: Safety Warning And Operation Decals

    In the event any decal becomes il- legible or comes off, contact your Polaris dealer for a replacement. Any safety de- cal needing replacement will be provided by Polaris at no charge. The part number...
  • Page 12 SAFETY WARNING AND OPERATION DECALS 7077919 E1997...
  • Page 13 SAFETY WARNING AND OPERATION DECALS...
  • Page 14 SAFETY WARNING AND OPERATION DECALS WARNING READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE. IF YOU DO NOT HAVE THE OWNER’S MANUAL FOR THIS VEHICLE. CALL 1-800-342-3764 TO HAVE ONE PROVIDED AT NO EXTRA CHARGE.
  • Page 15 SAFETY WARNING AND OPERATION DECALS...
  • Page 16 SAFETY WARNING AND OPERATION DECALS Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7078253 WARNING OVER-LOADING CAN CAUSE STEERING, “IMPROPER TIRE PRESSURE OR TIPPING AND BRAKING PROBLEMS RE- OVERLOADING CAN CAUSE LOSS...
  • Page 17 SAFETY WARNING AND OPERATION DECALS This decal is found only on models with dual racks. WARNING LOAD DISTRIBUTION WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating char- acteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability.
  • Page 18 SAFETY WARNING AND OPERATION DECALS This decal is found on models with only rear racks. WARNING RACK LOAD WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability.
  • Page 19 SAFETY WARNING AND OPERATION DECALS ATTENTION DOPERATION OF THIS VEHICLE WITHOUT DLiutilisation de ce véhicule sous liélément THE FILTER ELEMENT WILL SEVERELY filtre endommage sévèrement le moteur. DAMAGE THE ENGINE. DNettoyer souvent le filtre à air, surtout dans DCLEAN AIR FILTER OFTEN, MORE FRE- des situations poussiereuses.
  • Page 20 SAFETY WARNING AND OPERATION DECALS MOVING PARTS HAZARD UNDER BELT-CLUTCH GUARD. TO PREVENT SERIOUS INJURY, DO NOT OPERATE VEHICLE WITH GUARD REMOVED. DO NOT MODIFY ENGINE OR CLUTCH. DOING SO CAN CAUSE PART FAILURE, POSSIBLE IMBALANCE, AND EXCESSIVE ENGINE RPM WHICH CAN RESULT IN SERIOUS INJURY OR DEATH.
  • Page 21 Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory setting: 40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). 7073761 MANUFACTURED OVERRIDE BY: POLARIS IND OVERRIDE SWITCH SWITCH DATE: Reverse Speed is Reverse override limited.

  • Page 22: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully.

  • Page 23: Operation Warnings

    HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then reg- ularly practice the skills learned in the course and the operating tech- niques described in the Owner’s Manual.
  • Page 24 OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 25 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 26 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 27 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a se- vere head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 28 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 29 OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 30 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 31 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 32 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip- pery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the...
  • Page 33 OPERATION WARNINGS WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Own- er’s Manual. See page 63 . Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 34 OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 65 through 68. Always check the terrain carefully before you start up any hill.
  • Page 35 OPERATION WARNINGS WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 67. NOTE: A special technique is required when braking as you go downhill.
  • Page 36 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mas- tered the turning technique as described in the Owner’s Manual on level ground.
  • Page 37 OPERATION WARNINGS WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 38 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 39 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 40 All parts and accessories added to this vehicle should be gen- uine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

  • Page 41: Operation Warnings

    OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an ac- cident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.

  • Page 42: Vehicle Identification Numbers

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

  • Page 43: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Engine Electrical Switches RUN OFF Push Up to Start 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re- verse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.NOTE: The override switch also allows activation of Demand 4 Drive (All Wheel Drive) in reverse, if Demand 4 Drive switch is on.
  • Page 44 Light Switches and Indicator Lights Switches Each Polaris ATV has a main switch. It is located on the right hand side of the ma- chine and operated with a key. The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams.
  • Page 45 Electronic Speedometer Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer mea- sures distance in miles and kilometers as well as hours of operation. To display each mode, press the button on the face of the speedometer once to “toggle”...
  • Page 46 This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle...
  • Page 47 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through the Master Cylinder plastic reservoir, and should be main- Reservoir tained between the indicated max and min marks on the reservoir.
  • Page 48 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake Maximum 1.Squeeze the left hand brake lever two Minimum or three times and hold it. 2.Rotate the park brake lock into the notches on the master cylinder body. Release the brake lever. 3.To release the parking brake lock, squeeze the brake lever.

  • Page 49: Auxiliary Brake

    Auxiliary Brake Pedal Your Polaris ATV has an auxiliary brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inop- erative.
  • Page 50 CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation Shift patterns depend on the type of vehicle you own. Please check your Owner’s Shift Patterns Manual Supplement to define your ma- chine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter.

  • Page 51: Demand 4 Drive

    AWD Switch Exclusive Demand 4 Drive System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch on the right handlebar. When the switch is “off” the 4x4 is in 2 wheel drive at all times. When the switch is “on”...

  • Page 52: Pvt System

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

  • Page 53: Engine Cooling System

    NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing rec- ommendations for the freeze protection required in your area.
  • Page 54 Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. IMPORTANT: Al- ways follow the manufacturer’s mixing recommendations for the freeze protection...
  • Page 55 CAUTION: To avoid serious engine damage always top off the oil level when refueling. CAUTION: On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
  • Page 56 CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

  • Page 57: Oil System

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more fre- quently if Polaris Premium 4 is not used. You will also need to follow the manufac- turers recommendations for ambient temperature operation.
  • Page 58 CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) Run engine for two to three minutes until warm. Shut engine off. Place a drain pan beneath the plug and remove it. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. Allow oil to drain completely.
  • Page 59 19. Dispose of used filter and oil properly. Fuel Filter and Oil Filter All Polaris ATVs are equipped with a unique in-line fuel filter. These filters should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean these filters.
  • Page 60 Premium 2-cycle oil. Premium 2-Cycle Oil Polaris also has a TC-W3 premium oil available for use in all of our 2 cycle products. We highly recommend its use if premium gold synthetic is not used. The only oil recommended for this ATV is Polaris brand oil.

  • Page 61: Recoil Starter

    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 re- stores compression for starting.

  • Page 62: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained.

  • Page 63: Starting The Engine

    STARTING THE ENGINE Procedure for Starting a Cold Engine 1.Place the transmission in neutral and push the vehicle to a level surface. 2.Lock the parking brake. 3.Turn the fuel tank valve to ON. 4.Sit on the vehicle. “OFF” “HALF” Choke Lever Top View “FULL”...

  • Page 64: Vehicle Break In Period

    VEHICLE BREAK-IN PERIOD 2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period.
  • Page 65 VEHICLE BREAK-IN PERIOD 4-Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of op- eration, 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 66: Riding Gear

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

  • Page 67: Carrying Loads

    CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and car- go to maintain stable driving conditions.

  • Page 68: Cargo Weight Distribution

    CARGO WEIGHT DISTRIBUTION 2/3 of Load on 1/3 of Load on Rear Rack Front Rack WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load af- fects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

  • Page 69: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully.

  • Page 70: Riding

    RIDING 1.Sit upright with both feet on the footrests and both hands on the handlebars. 2.After starting the engine and allowing it to warm up, shift the transmission into gear. 3.Check your surroundings and determine your path of travel. 4.Release the parking brake. 5.Slowly depress the throttle with your right thumb and begin driving.

  • Page 71: Making Turns

    Making Turns Practice making turns at slow speeds. Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 72: Riding On Slippery Surfaces

    RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 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 73: Traveling Uphill

    RIDING Traveling Uphill 25_ Maximum Whenever traveling uphill always travel straight uphill and: 1.Avoid steep hills. 2.Keep both feet on the footrests. 3.Transfer your weight forward. 4.Proceed at a steady rate of speed and throttle opening. 5.Remain alert and be prepared to take emergency action. This may include quick dismounting of the ATV.
  • Page 74 RIDING Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1.Slow down. 2.Lean into the hill transferring your upper body weight toward the hill while keep- ing your feet on the footrests.

  • Page 75: Traveling Downhill

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

  • Page 76: Turning Around On A Hill

    RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.Stop and lock the parking brake while maintaining body weight uphill.

  • Page 77: Crossing Streams

    RIDING Crossing Streams Your Polaris ATV can operate through water up to depths reaching the footrests. Before fording streams always: 1.Determine water depths and current. 2.Choose a crossing where both banks have gradual inclines. 3.Proceed slowly, avoiding rocks and obstacles if possible.

  • Page 78: Trail Obstacles

    RIDING Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous.

  • Page 79: Backing Up

    RIDING Backing Up Backing Up 1.Whenever 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.Never activate override button while throttle is open. Loss of control may result. NOTE: This vehicle is equipped with a reverse speed limiter.

  • Page 80: Riding

    RIDING Parking on an Incline Whenever the Vehicle is Parked 1.Turn the engine off. 2.Place the transmission in gear. 3.Set the parking brake. 4.Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 5.Shut off fuel supply.

  • Page 81: Battery

    BATTERY Battery CAUTION Whenever removing the battery, discon- nect the negative (black) cable first. When reinstalling the battery, connect the nega- tive (black) cable last. Maintain Replenishing the Battery Fluid between upper and A poorly maintained battery will deteriorate lower level rapidly.

  • Page 82: Battery

    BATTERY Battery Removal 1.Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2.Remove the battery vent tube from the battery. 3.Disconnect the black (negative) battery cable first. 4.Disconnect the red (positive) battery cable next. 5.Lift the battery out of the ATV, being careful not to tip it sideways and spill any electrolyte.

  • Page 83: Noise Emission Control System Regulation

    USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your mod- el, see the Owner’s Manual Specification Supplement that came with your ma-...

  • Page 84: Maintenance

    MAINTENANCE Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1.Remove the clean out plugs located on the bottom of the muffler as shown above. 2.Place the transmission in neutral and start the en- gine. Purge accumulated carbon from the system by Clean Out Plugs momentarily revving the...
  • Page 85 MAINTENANCE Spark Arrestor (Cont.) WARNING DDo not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. DBecause of the increased fire hazard, make sure that there are no com- bustible materials in the area when purging the spark arrestor. DWear eye protection.

  • Page 86: Power Pig Tail

    2410022 and follow correct wire splicing procedures to avoid shorts in the wiring system. The power outlet and pigtail may be purchased from Polaris Pigtail using the following numbers: 2460442 outlet - 2410022; pigtail - 2460442...

  • Page 87: Periodic Maintenance Schedule

    CAUTION: Due to the nature of these adjustments, 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.
  • Page 88 MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Frequency Remarks Odometer Engine breather filter 20 hrs Monthly Inspect- -replace annually and as need- " (4-cycle) Brake pad wear 10 hrs/100 Monthly Inspect periodically miles Front and Rear Gearcase Oil 100 hrs Monthly Check monthly and change annually "...
  • Page 89 Adjust if necessary CAUTION: Due to the nature of these adjustments, 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. " More often under severe use, such as dirty or wet conditions...

  • Page 90: Lubrication Recommendations

    1. Engine Oil Polaris Fill oil tank. See page 47. As needed, (2-Cycle) Injection Oil when refueling 2.Engine Oil Polaris Pre- Add to proper level on dipstick. Check level dai- (4-Cycle) mium 4 Syn- See page 49. thetic 0W40 3. Brake Fluid DOT 3 Only Maintain level between fill lines.
  • Page 91 Semi-annually * More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 500 miles, or after submerging in water or before long periods of storage or after pressure washing.
  • Page 92 MAINTENANCE Lubrication Recommendations 4. Transmission (dipstick) Full Operating 4. Transmission Range (plug) 5. Front Gear Case 6. Front Prop Shaft (U-Joint) Fill plug 12. Rear Gear 7. Propshaft Yoke 10. Axle Cardan Case - Fill Hole Front Drive (AWD Models) 14.
  • Page 93 MAINTENANCE Lubrication Recommendations 15. Steering Post Bushings Lower 9. Demand 4 Hubs (4x4 only) Upper 13. Front A-Arm Pivot Shaft 11. Ball Joint 9. 4 O’clock position...
  • Page 94 MAINTENANCE Lubrication Recommendations 17. Swing Arm Bushings 16. Rear Axle Bearing INDEPENDENT REAR SUSPENSION 19. Lower Control 18. Upper Control 19. Lower Control 21. Rear Anti- 20. Rear Wheel Roll Bar Hub Bearing Carrier...
  • Page 95 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.

  • Page 96: Handlebar Adjustment

    MAINTENANCE Steering Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1.Locate handlebar bolts. On mod- els with a headlight pod, it will be necessary to remove the upper headlight pod. On other models remove the handlebar cover. 2.Loosen the four bolts.
  • Page 97 Rear Hub Retaining Nut(s) 100 Ft. Lbs. Rear Wheel Nuts 50 Ft. Lbs. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op- erations. Service work must be performed by your authorized Polaris dealer.
  • Page 98 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Rear Spring Adjustment Adjustment Rear Spring Adjustment...
  • Page 99 MAINTENANCE Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. Remove seat. Grasp rear of side panel near rear cab. Step 1. With a quick and firm motion, pull the panel forward and outward to disengage the two rear...
  • Page 100 MAINTENANCE Air Cleaner Trail Blazer Secondary (Main) Filter Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine. Secondary filter removal and installation procedure: 1.Remove ATV seat.
  • Page 101 MAINTENANCE Air Filter Service Trail Blazer Gray Collar 1.Release seat latch and lift up on the rear of the seat and remove Yellow Boot seat. Intake Silencer 2.Remove the primary air filter box. 3.Remove the yellow pre-cleaner foam boot, held in place by a Airbox Retainer gray collar, from the air box.
  • Page 102 MAINTENANCE Air Filter Service Scrambler 500 1.Remove seat. 2.Release clips and remove cover. Main Filter 3.Loosen clamp and remove filter 4.Remove fabric type pre-filter from main filter. Wash pre-filter in Pre-Filter soapy water and dry it. 5.Reinstall pre-filter over main filter. Replace main filter as required.
  • Page 103 MAINTENANCE Air Filter Service - Sportsman 500, Scrambler 500 1.Remove seat. 2.Remove spring Pre--filter clamps securing the airbox lid and re- move lid. 3.Loosen clamp and remove filter 4.Remove fabric type pre-filter from main filter. Wash pre-filter Main Filter in soapy water and dry it.

  • Page 104: Steering Inspection

    5.If this measurement needs to be adjusted, contact your dealer for service. WARNING: Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments.

  • Page 105: Front Brake

    Always fill the reservoir as indicated whenever the cover is loos- ened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid (PN 2870990).
  • Page 106 Should the main system fail, the rear brake can be activated by de- pressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have hydraulic brake systems. The hydraulic auxiliary brake system will not require ad- justment.
  • Page 107 MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1.Before adjusting the oil pump, check engine idle RPM and carburetor ad- justments which are found in the own- er’s manual supplement. 2.Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″ - 1/8″...
  • Page 108 Lever Arm Oil Pump Bleeding Procedure 1.Fill the oil reservoir with Polaris injector oil. 2.Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil reservoir and supply line have been completely run out of oil.

  • Page 109: Throttle Cable Adjustment

    MAINTENANCE Throttle Cable Adjustment 250 and 400 Engines Vehicles with 250 and 400 engines do not utilize a cable sleeve jam nut. You will need to bottom the cable to the carburetor slidevalve cap. Adjust at throttle cable adjuster near the throttle block. Engine Choke Adjustment 2-Cycle Engines With the dash mounted choke control toggle flipped to full off position, the choke...
  • Page 110 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1.Warm up the engine by running the vehicle approximately five minutes. 2.Place the transmission in gear Idle with the parking brake applied.
  • Page 111 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satis- factory, and all other conditions are favorable, the carburetor can be ad- justed as follows: 1.Warm up the engine by running the vehicle approximately five min- utes.

  • Page 112: Spark Plugs

    MAINTENANCE Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 113 3.Remove transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly. 4.Clean and reinstall the drain plug. 5.Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) until oil reaches the bottom of the filler hole. 6.Check for leaks.
  • Page 114 ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478). Transmission Oil Changing Procedure 1.Remove skid plate if required.

  • Page 115: Front Gearcase Lubrication

    MAINTENANCE Front Gearcase Lubrication Fill plug The front gearcase fill plug is located as shown. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. With the ATV on a level surface, remove fill plug and check the lubricant level.
  • Page 116 MAINTENANCE Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil Counter should be added or changed as Crankcase Drain Balance necessary. The oil should be Drain changed annually, especially be- fore off season storage. If the ma- chine is used in wet conditions the oil should be checked more fre- quently.

  • Page 117: Wheel Installation

    MAINTENANCE Wheel Removal Procedure 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 footrest frame. 4.Remove the wheel nuts and remove the wheel. Wheel Installation 1.With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub.

  • Page 118: Tire Inspection

    MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability. When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect ATV handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″...
  • Page 119 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION: Never wash the chain with a high pressure washer or gasoline. Dam- age to the O-rings will result, causing premature wear and drive chain failure.
  • Page 120 MAINTENANCE Rear Drive Chain Slack Adjustment (Models with Concentric Drive) CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain.

  • Page 121: Headlight Lamp Replacement

    MAINTENANCE Headlight Lamp Replacement WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service while headlight is hot.

  • Page 122: Headlight Adjustment

    MAINTENANCE Headlight Lamp Replacement Trail Blazer, Sport 1.Remove front cover and unplug the light harness. 2.Remove rubber cap from back of headlight to reveal retention screw. 3.Remove small phillips head screw, and carefully remove bulb from housing. 4.Insert new bulb into housing and tighten retention screw, install rubber cap. 5.Reconnect light harness.
  • Page 123 MAINTENANCE Headlight Lamp Replacement Trail Boss 1.Remove the seat. 2.Remove the plastic panel surround- ing the upper portion of the gas tank by first removing the gas tank cap. 3.Remove the Phillips head screws on either side of the panel at the junc- tion of this panel, the lower panels, and the rear of the front fenders.
  • Page 124 MAINTENANCE Headlight Replacement (cont.) 9.Carefully unplug the socket from the lamp. Remove the panel and set it aside. 10.Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 11.Remove bolt and disengage the wire bail holding the headlight lamp in place and move it out of the way.

  • Page 125: High Beam Headlight Adjustment

    MAINTENANCE Headlight Lamp Replacement Xplorer 400, Sportsman 500, Magnum 500 Snap pins into tabs Position Slip O-Ring knob in over pin slot and Route plug secure in over Adjustment locking handlebar Knob Stop tabs 1.Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver.

  • Page 126: Headlight Housing Replacement

    MAINTENANCE Headlight Housing Replacement 1.Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access.
  • Page 127 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. Lens Cover 1.From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2.Remove lamp and replace it with recom- mended lamp.

  • Page 128: Cleaning Your Atv

    MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing 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 and warning labels.

  • Page 129: Carburetor Adjustments

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

  • Page 130: Troubleshooting

    Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START...

  • Page 131: Warranty

    This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.

  • Page 132: Warranty

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 133: Index

    INDEX Engine Cooling System ..45-46 Lubricant, 2cycle ....Air Cleaner ....92-95 Lubrication Recommendations .

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