Polaris 2004 Sportsman 700 EFI Owner's Manual

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be
attached to the owner’s manual on the next page. If you cannot
locate this card, or if it has been removed, please call
1-800-342-3764 for assistance.

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Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

3

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.

Polaris Recreational Vehicles

S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S RANGER utility vehicles
S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)
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 machine we’ve ever
produced.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.

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VEHICLE IDENTIFICATION NUMBERS

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

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. See your Polaris dealer.

NOTE: Record your vehicle’s ID numbers and key number in the
spaces provided.

1. Frame VIN:

_________________________________________________________________________

2. Engine Serial Number:

_________________________________________________________________________

3. Key Number:

_________________________________________________________________________

4. Vehicle Model Number:

_________________________________________________________________________

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31XX

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2

5

TABLE OF CONTENTS

WELCOME 3........................................

VEHICLE IDENTIFICATION NUMBERS 4...............

SAFETY 6..........................................

FEATURES AND CONTROLS 32......................

OPERATION 47.....................................

EMISSION CONTROL SYSTEMS 64...................

MAINTENANCE AND LUBRICATION 65................

TROUBLESHOOTING 103............................

POLARIS PRODUCTS 105............................

SPECIFICATIONS 109................................

W A RRANTY 110.....................................

INDEX 117..........................................

6

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any
of the decals depicted in this manual differ from the decals on your
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. The part number is printed on the decal.

WARNING

7079083

E1997, 2000

IF OWNER’S MANUAL IS MISSING, CONT ACT

A POLARIS DEALER FOR A REPLACEMENT.

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 ar e
under age 16.

WARNING

WARNING

7077920

7

SAFETY

Safety Decals and Locations

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).

Reduce speed and al low greater distance for braking when carrying
cargo. Overloading or carrying tal l, off-center, or unsecured loads
will inc rease your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. With
dual racks, load distribution 1/3 front 2/3 rear is best. For stability
on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be c areful if load extends over the si de of the rack.

Read Owner’s Manual for more detailed loading information

WARNING

7079084

ATTENTION

S Operation of this vehicle without the air filter

element will severely damage the engine.

S Clean pre-filter element often, more

frequent cleaning required in dusty
conditions. Do not operate vehicle without
pre-filter.

S Operation of this vehicle without engine

breather filter(s) can cause engine
damage. Consult owner’s manual or dealer
for details.

7172251

8

SAFETY

Safety Decals and Locations

Moving parts haz ard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard r emov ed.

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.

NO STEP

7078689

S DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may res ult causing severe injury
or death. Tow only from tow hooks or hitch.

S Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

7170912

WARNING

WARNING

9

SAFETY

Safety Decals and Locations

ALL WHEEL

DRIVE

SWITCH

Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See y our Owner’s
Manual.

7079780

7079604

7170509

TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

WARNING

Pushing reverse
override button
may cause
sudden in­creases in pow­er and traction if
too much
throttle is ap­plied. Loss of
control or for­ward flipover
may result, es­pecially in
AWD. See Own­er’s Manual.

MANUFACTURED
BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.

7171492

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST
PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

10

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV 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 .

Select an approved helmet that meets
or exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards
Institute label (ANSI z90.1), or the
Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for
proper eye protection. A pair of
goggles or a helmet face shield offer
the best protection for your eyes. They
should be kept clean and be of
shatterproof design (bearing the
markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and
protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.

1

2

3

4

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11

SAFETY

Operator Safety

WARNING

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 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.

Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You
were also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of t his vehicle in your
area.

We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

12

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.

WARNING

The safety alert warning indicates a potential hazard that may
result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the
vehicle.

IMPORTANT

IMPORTANT will alert you to important information or
instructions.

NOTE: A note will alert you to key information or instructions.

13

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instructor .

Contact an authorized Polaris ATV 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 ATV.
S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safe­ty training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in t his manu-

al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.

14

SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. C heck the ter-

rain carefully before ascending a hill. Never climb hills with exces­sively slippery or loose surfaces. Shift your weight forward. Never
open the throttle suddenly or make sudden gear changes. Never go
over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the t errain carefully before you start down a hill.
Shift your weight backward. 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. Travel straight down the hill when pos­sible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turn­ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Always dismount
on the uphill side, or to either side if the ATV is pointed straight
uphill. Turn the ATV around and remount following the procedure
described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skid­ding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sud­den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.

15

SAFETY

Operator Safety

S Wet brakes may have reduced stopping ability. Test the brakes after

leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.

S Always check for obstacles or people behind the ATV before operat-

ing in reverse. When it’s safe to proceed in reverse, move slowly
and avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con­sumer Product S afety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.

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 ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.

The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the
handling characteristics of the vehicle. Use only Polaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.

16

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.

For more information about the training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN

HAPPEN

Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an 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.

17

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Carrying a passenger on an ATV.
WHAT CAN

HAPPEN

Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the operator
and/or passenger.

HOW TO AVOID THE

HAZARD

Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.

WARNING

POTENTIAL HAZARD
Operating an ATV on paved

surfaces, including
sidewalks, paths, parking
lots, and driveways.

WHAT CAN

HAPPEN

ATV tires are designed for
off-road use. Operating on paved
surfaces may adversely affect the
handling of the A TV and could result in loss of control, accident,
and/or injury.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.

18

SAFETY

Operator Safety

WARNING

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. In many states it’s illegal to
operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD
Operating this ATV without

wearing an approved helmet,
eye protection and protective
clothing.

WHAT CAN

HAPPEN

Operating an ATV without an
approved helmet increases
the risk of a severe head
injury or death in the event of
an accident.

Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.

HOW TO AVOID THE

HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,

boots, long-sleeved shirt or jacket, and long pants.

19

SAFETY

Operator Safety

WARNING

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.

HOW TO AVOID THE

HAZARD

Never consume alcohol or drugs before or while operating an
ATV.

WARNING

POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN

HAPPEN

Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident causing severe
injury or death.

HOW TO AVOID THE

HAZARD

Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.

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.

20

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN

HAPPEN

Poor maintenance increases the possibility of an accident or
equipment damage.

HOW TO AVOID THE

HAZARD
Always inspect your ATV before each use to make sure it’s in

safe operating condition.
Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

WARNING

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.

If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury .

HOW TO AVOID THE

HAZARD
Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

21

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Failure to use extra caution

when operating the ATV 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. Always be alert to changing terrain conditions.

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.

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

22

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.
Practice turning at slow speeds before attempting to turn at faster

speeds.
Never turn at excessive speed.

WARNING

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 25_.

Practice on smaller hills before attempting large hills.

23

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.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other
side of the hill.

24

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. NOTE: A
special technique is required when
braking while traveling downhill.
See page 58.

Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill
when possible.

25

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

NeverattempttoturntheATV
around on any hill until you’ve
mastered the turning technique
(on level ground) as described in
the owner’s manual. See page 59.
Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill.
When crossing the side of a

hill:

Always follow proper procedures as described in the owner’s
manual.

Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.

26

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.
Apply the brakes.
Lock the parking brake when fully stopped.
If the ATV begins rolling

backwards:
Keep weight uphill.
Never apply engine power.
Never apply the rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the rear brake as well, and then lock

the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight

uphill.
Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 59.

27

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. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.

WARNING

POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN

HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE

HAZARD

On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.

28

SAFETY

Operator Safety

WARNING

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. If it’s
unavoidable to enter water that exceeds the recommended
maximum depth (see page 60), travel slowly, balance your weight
carefully, avoid sudden movements, and maintain a slow and
steady forward motion. Do not make sudden turns or stops, and
do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN

HAPPEN

The ATV could collide with an obstacle or person, resulting in
severe injury.

HOW TO AVOID THE

HAZARD

Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back slowly.

29

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or

uneven tire pressure.
WHAT CAN

HAPPEN
Use of improper tires, or operation of the A TV with improper or

uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE

HAZARD

Always use the size and type of tires specified for the ATV in the
owner’s manual.

Always maintain proper tire pressure as described in the owner’s
manual and on safety decals.

WARNING

POTENTIAL HAZARD
Operating the ATV with improper modifications.
WHAT CAN

HAPPEN
Improper installation of accessories or modification of the ATV

may cause changes in handling, which could lead to an accident.
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. See your authorized Polaris
ATV dealer for more information.

30

SAFETY

Operator Safety

WARNING

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.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow a

greater distance for braking.
Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer.

WARNING

POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN

HAPPEN

Severe injury or death can result if the ATV and/or the operator
fall through the ice.

HOW TO AVOID THE

HAZARD
Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to
support the machine and its operator, as well as the force created
by a moving vehicle, exercise extreme caution.

31

SAFETY

Operator Safety

WARNING

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.

WARNING

Safe operation of this rider-active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturn and loss of control, which could result in severe injury or
death.

CAUTION

Exposure to the hot components could result in a fire. Always
keep combustible materials away from the exhaust system.

32

FEATURES AND CONTROLS

Engine Electrical Switches

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.

Mode/Reverse Override Switch (1) - This vehicle is equipped with a
reverse speed limiter system. To gain additional power while backing,
depress the override switch. NOTE: The override switch also allows
activation of All Wheel Drive in reverse, if the AWD switch is on.
This switch is also used to toggle through the different modes of the
rider information center. See page 41.

Engine Stop Switch (2) - The engine will
not start or run when the switch is in the
OFF position. Its purpose is to provide the
operator with a quick means of engine
shutdown in case of an emergency .
NOTE: The cooling fan motor does not
shut off when the stop switch is used to
stop the engine. Turn off the main ignition switch to turn off the
cooling fan motor.

Main Switch (3) - To start the engine, slide the stop switch to t he
center RUN position and turn the main key switch clockwise past the
ON position. Release the key when the engine starts.

NOTE: Both the main switch and the emergency engine stop switch
will shut off all electrical power to the vehicle, i ncluding lights. To
stop the engine, slide the stop switch either right or left to the OFF
position.

1

3

2

RUN

OFFOFF

2

33

FEATURES AND CONTROLS

WARNING

Operating an ATV with sticking or improperly operating throttle
controls could cause an accident and lead to severe injury or
death.

Never start or operate an A TV with a sticking or improperly
operating throttle. Always contact your dealer for service if throttle
problems arise.

Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks during
operation. Always check the lever for free movement and return
before starting the engine. Also check occasionally during
operation.

Throttle Lever

Engine speed and vehicle movement
are controlled by pressing the
throttle lever (1). 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 t he 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.

WARNING

Modifications to the ETC could result in failure to perform as
designed, which could result in severe injury or death. Do not
attempt to modify the ETC system or replace it with any after
market throttle mechanisms. Always ensure that the throttle
cable is properly installed to the ETC.

1

34

FEATURES AND CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the
lights on and off and to switch the lights from HI to LO. NOTE: The
lights won’t work unless the key is in the ON position and the auxiliary
shut-off switch is in the RUN position.

WARNING

Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness.

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 type brakes that are
activated by only one lever.

Always test brake lever travel and
master cylinder fluid level before riding.
When squeezed, the lever should feel firm. Any sponginess would
indicate a possible fluid leak or low master cylinder fluid level, which
must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of
braking, which could cause an accident. Never operate the ATV
with a spongy-feeling brake lever.

1

35

FEATURES AND 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. When
fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the ATV must be on level
ground with the handlebars straight. If the fluid level is low add DOT 3
brake fluid only. See page 109 for t he part numbers of Polaris products.

WARNING

After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury.

1

2

36

FEATURES AND CONTROLS

Parking Brake

WARNING

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.

Setting the Parking Brake

1. Place the transmission in park.

2. Squeeze and release the brake
lever (1) two or three times, then
squeeze and hold.

3. Push the park brake lock (2)
forward to engage the brake.
Release the brake lever.

4. To release the parking brake
lock, squeeze and release the brake
lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

it parked on a hill. Another option is to park the ATV in a sidehill
position.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

1

2

37

FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the auxiliary brake when backing down a
hill may cause rear tipover , which could result in serious injury or
death.

Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward. The
rear wheels may skid and slide sideways, causing loss of control
and serious injury or death.

Your Polaris ATV has an
auxiliary brake (1) for added
safety. It’s located on the
inside of the right floor board
and is operated by the right
foot. The auxiliary brake
serves as a backup to the main
brake system if the main
system becomes inoperative.

If the rear wheels slide while
using the auxiliary brake,
reduce brake pedal pressure to brake the rear wheels without skidding.

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat or near the auxiliary brake.
Maintain the fluid level between the maximum and minimum m arks.

1

38

FEATURES AND CONTROLS

Fuel Tank

The fuel tank filler cap (1) is located
directly below the handlebar. Use either
leaded or unleaded gasoline with a
minimum pump octane number of
87=(R+ M/2) octane.

Fuel Filter

The in-line fuel filter should be replaced by
your dealer after every 200 hours of
operation and any time the fuel becomes
contaminated with dirt or debris. Do not
attempt to clean the fuel filter.

1

39

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the
vehicle.

H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park

To shift into HIGH or PARK, you must first apply the auxiliary brake
to activate the high/park lock-out mechanism. When shifting out of
HIGH or PARK, it’s not necessary to apply the brake.

Whenever the ATV is left unattended, always place the transmission in
park and lock the parking brake.

CAUTION

Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear. Apply the auxiliary brake if
shifting into HIGH or PARK.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour for extende d periods of
time.

H

N

P

L

R

1

40

FEATURES AND CO NTROLS

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are
equipped with a unique,
Polaris-exclusive, On-Demand All
Wheel Drive system, which is
activated by the A WD switch (1) on
the right handlebar. When the
switchisoff,theATVisin
two-wheel drive at all times. When the switch is on, the ATV is in
AWD and the AWD indicator light in the instrument cluster will be on.

When in AWD, the front gearcase will automatically engage any time
the rear wheels lose traction. When the rear wheels regain traction, the
front gearcase will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if
the AWD switch is on. See page 32.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging the Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle’s electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the front gearcase is moving, it will not disengage until the rear
wheels regain traction.

Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause
severe drive shaft and gearcase damage. Always switch to A WD
while the rear wheels have traction or are at rest.

1

41

FEATURES AND CONTROLS

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster measures
distance in miles as well as hours of operation. It also includes a
reverse speed limiter function that limits the ATV’s speed to
approximately 7-9 mph. Refer to page 32 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the
needle flashes when a warning condition exists.

3. Speedometer

CAUTION

High water pressure may damage ATV components. W ash the
ATV by hand or with a garden hose using mild soap.

Certain products, including insect repellants and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not
use alcohol to clean the instrument cluster. Do not allow insect
sprays to come into contact with the lens. Immediately clean off
any gasoline that splashes on the instrument cluster.

2

3

1

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All
segments will light up for 2.5 seconds at start-up.

NOTE: 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 - As the shift lever is moved, this indicates the
gear the transmission is in:

H = High Range
L = Low Range
N = Neutral
R = Reverse
P=Park

2. AWD Indicator - This
indicator illuminates
when the electrical
portion of the AWD
system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode In dicator

5. Low Battery and Over Voltage - This warning usually indicates
that the ATV is operating at an RPM too low to keep the battery
charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Driving at a higher RPM or
connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge show the level of
fuel in the fuel tank. When the last segment clears, a low fuel
warning is activated. All segments will flash, FUEL will display
in the LCD, and the speedometer needle will blink. Refuel
immediately.

8. Check Engine Warning Indicator - This indicator serves two
purposes. The word HOT displays if the engine overheats. It also
appears if an EFI-related fault occurs. Do not operate the ATV if
this warning appears. Serious engine damage could result.

9. Mode Indicator

8

5

4

3

1

6

2

9

7

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes:
Mode 1 - Odometer
Mode 2 - Tripmeter
Mode 3 - Total Service Hours
Mode 4 - Tachometer
The reverse override button on the left handlebar is also the mode

button. NOTE: If using the mode button to program the rider
information center, or to toggle through the options, the machine
cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

The trip meter records the miles traveled by the ATV on each trip if it’s
reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the total
changes to 0 . NOTE: In the Rider Information Center, the trip meter
display contains a decimal point, but the odometer displays without a
decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

Mode 4 - Tachometer

The engine R PM is displayed digitally. NOTE: Small fluctuations in
the RPM from day to day may be normal because of changes in
humidity, t emperature and elevation.

44

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return
your ATV to your dealer for all major repairs.

As long as the gauge is in the diagnostic mode, the wrench icon will
remain lit.

To leave the diagnostic mode, either shift the machine out of neutral or
turn the key switch off and on. NOTE: Any movement of the tires
will also take the m achine out of the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Set the park brake and shift the transmission into neutral.

3. Hold the mode/reverse override button and turn the key switch on.

4. Release the switch as soon as the display is activated.

The initial screen display refers to the software version installed in
your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic
screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the
AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic
This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval
The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine
maintenance. When your vehicle leaves the factory, this feature is set at
50 hours. You must enable the programmable service interval before it
can be used.

Once the service interval mode is set with the hours when service is
due, the hours of actual engine operation are subtracted from the set
hours until 0 is reached. When the counter reaches 0, the wrench icon
will flash quickly for 5 seconds each time the vehicle is started as a
reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the
wrench icon flashes. When it begins to flash, release the button. The
setting will increase by one hour each time the button is pressed.
Pressing and holding the button will allow the numbers to escalate
much faster. When the desired time increment is displayed, release the
button and wait for the wrench to stop flashing. When the wrench
stops blinking, your service hours are set. NOTE: If you scroll past
the intended number, hold the button down until the count turns over to

0. You can then reset the number.
If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold t he mode
button for approximately 7 seconds until the word OFF appears in the
Rider Information Center.

Screen 6: Miles/Kilometers toggle
The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as
KM or MP. To change, hold in the mode button until the letters flash,
then press and release the button once. When the display stops
flashing, the mode has been set.

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Special EFI Diagnostic Mode

The EFI diagnostic mode is for informational purposes only. Please
see your Polaris dealer for all major repairs. To download blink codes
(failure codes) from the EFI module:

1. Place the transmission in PARK, turn t he engine off and turn the
key switch to the ON position.

2. Turn the key switch off and on three times in less than five
seconds, then leave the switch on. Any blink code numbers stored
in the EFI module will display, one at a time, in the alphanumeric
display. The word END will display after all codes have been
transmitted.

Blink
Code

Failure Description Blink

Code

Failure Description

- No RPM Signal

54 Engine Temp Lamp: Open Load

21 Loss of Synchronization 54 Engine Temp Lamp: Short Circuit

to Ground

45 Barometric Pressure Sensor:

Circuit Low Input

54 Engine Temp Lamp: Short Circuit

to Battery

46 Barometric Pressure Sensor:

Circuit High Input

55 Diag Lamp: Open Load

22 TPS: Open or Short Circuit to

Ground

55 Diag Lamp: Short Circuit to

Ground

22 TPS: Short Circuit to Battery 55 Diag Lamp: Short Circuit to

Battery

23 RAM Error: Defective ECU 56 Pump Relay: Open Load

42 Engine Temp Sensor Circuit:

Short to Ground

56 Pump Relay: Short Circuit to

Ground

42 Engine Temp Sensor Circuit:

Open or Short to Battery

56 Pump Relay: Short Circuit to

Battery

51 Injector 1: Open Load 58 Cooling Fan: Open Load

51 Injector 1: Short Circuit to Ground 58 Cooling Fan: Short Circuit to

Ground

51 Injector 1: Short Circuit to Battery 58 Cooling Fan: Short Circuit to

Battery

52 Injector 2: Open Load 41 Intake Air Temp Sensor: Open or

Short Circuit to +Sensor Voltage

52 Injector 2: Short Circuit to Ground 41 Intake Air Temp Sensor: Short

Circuit to Ground

52 Injector 2: Short Circuit to Battery 61 END

47

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain
conditions.

Always exercise extreme caution whenever handling gasoline.
Always refuel with the engine stopped, and outdoors or in a well

ventilated area.
Do not smoke or allow open flames or sparks in or near the area

where refueling is performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Engine

exhaust fumes are poisonous and can cause loss of
consciousness or death in a short time.

WARNING

The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

48

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is defined as the first ten
hours of operation, or the time it takes to use the first two full t anks of
gasoline. No single action on your part is as important as following
the procedures for a proper break-in. Careful treatment of a new
engine will result in more efficient performance and longer life for the
engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.

CAUTION

Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 synthetic Oil or another 0W-40 API certified SH oil.
Never substitute or mix oil brands.

1. Fill the fuel tank with gasoline. See page 38.

2. Check the engine oil level on the dipstick. See page 73. Add oil
if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 49.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20
hours or 200 miles.

49

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done 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
working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel tank and engine oil level - Fill both to their proper levels.

3. All brakes - Check operation, adjustment and fluid levels (includes
auxiliary brake).

4. Throttle - C heck for free operation and closing.

5. Headlight/Taillight/Brakelight - Check operation of all indicator
lights and switches.

6. Engine stop switch - Check for proper function.

7. Wheels - Check for tightness of wheel nuts and axle nuts; check
that axle nuts are secured by cotter pins.

8. Air cleaner element - Check for dirt; clean or replace.

9. Steering - Check for free operation, noting any unusual looseness
in any area.

10. Loose parts - Visually inspect the vehicle for any damaged
components or loose nuts/bolts or fasteners.

11. Riding gear - Wear a helmet, goggles and protective clothing.

12. Engine coolant - Check for proper level at the recovery bottle.

50

OPERATION

Starting the 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 with the transmission in

PARK.

2. Lock the park brake, sit on the vehicle and turn the engine stop
switch to RUN.

NOTE: Do not press the throttle while starting the engine.

3. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the vehicle starts. If the engine does not start, release the
key, allowing it to return to the ON position, and wait five seconds.
Activate the starter for another five seconds if necessary. Repeat
this procedure until the engine starts.

CAUTION

Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. Water in the bottom of
the crankcase 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.

51

OPERATION

Hauling Cargo

Your ATV 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 outlined in the
specifications section of the owner’s manual and on the safety decals.

Cargo weight should be evenly distributed (1/3 on the front rack and
2/3 on the rear rack) and mounted as low as possible. When operating
over rough or hilly terrain, reduce speed and cargo weight to maintain
stable driving conditions. Do not obstruct the headlight beam with
cargo.

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend
belt life.

2/3

1/3

52

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:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or hilly
terrain, reduce speed and cargo to maintain stable driving
conditions. Carrying loads on one rack only increases the
possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.
Carrying loads high on the racks raises the center of gravity of
the vehicle and creates a less stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads
can create unstable operating conditions, which could result in
loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED
LOADS. When handling off-centered loads that cannot be
centered, securely fasten the load and operate with extra caution.
Always attach the tow load to the hitch point designated for your
vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle. Avoid terrain or situations that may require
backing downhill.

USE EXTREME CAUTION when operating with loads that extend
over the rack sides. Stability and maneuverability may be
adversely affected, causing the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when
carrying loads on the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass surface. Vehicle speed should
never exceed 5 mph (8 kph) when towing loads in rough terrain,
while cornering, or while ascending or descending a hill.

53

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. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin
driving. Vehicle speed is controlled by the amount of throttle
opening.

6. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.

54

OPERATION

Driving Safely

Making Turns

Your ATV 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.
To turn, steer in the direction
of the turn, leaning your upper
body to the inside of the turn
while supporting your weight
on the outer footrest. This
technique alters the balance of
traction between the rear
wheels, allowing the turn to be
made smoothly. The same
leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn
at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in
vehicle overturn and lead to serious injury. Avoid turning at sharp
angles. Never turn at high speeds.

55

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. Engage AWD before
wheels begin to lose
traction.

3. Maintain a high level
of alertness, reading the
trail and avoiding quick,
sharp turns, which can cause
skids.

4. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if the AWD is engaged
while the wheels are spinning. Always allow the rear wheels to
stop spinning before engaging AWD, or engage AWD before
wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.

Never apply the brakes during a skid. Do not operate on
excessively slippery surfaces. Always reduce speed and use
additional caution.

56

OPERATION

Driving Safely

Traveling Uphill

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. Remain alert and be prepared to take emergency action. This may
include quick dismounting of t he vehicle.

WARNING

Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure 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.

25_ Maximum

57

OPERATION

Driving Safely

Sidehilling

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.

Sidehilling can be the m ost dangerous type of driving encountered and
should be avoided if at all possible. If you do enter into a situation
where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!

58

OPERATION

Driving Safely

Traveling Downhill

WARNING

Excessive speed when traveling downhill can cause loss of
control and serious injury or death.

When traveling downhill, follow these precautions:

1. Transfer your weight to the rear.

2. Drive straight down the hill.

3. Slow down. Squeeze the brake lever gradually.
WARNING: Applying the brakes too firmly may cause the rear

wheels to lock, which could result in loss of control.

Before operating your ATV, learn how the auxiliary brake works in
case you lose your normal service brakes.

59

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.

If the vehicle stalls while climbing a hill, never back it down t he hill!
One maneuver that can be used when you must turn around while
climbing a hill is the K-turn:

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the service brake, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill
side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed
with the service brake, until the vehicle is on more level ground.

8’

Uphill

60

OPERATION

Driving Safely

Driving Through Water

Your ATV 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. Choose a crossing where
both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 65. The following areas
need special attention: engine oil, transmission oil, front and rear
gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart.

If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service before
starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing
water. If you cannot avoid water that exceeds the recommended
maximum depth, go slowly, balance your weight carefully, avoid
sudden movements, and maintain a slow and steady forward motion.
Do not make sudden turns or stops, and do not make sudden throttle
changes.

If your vehicle becomes immersed, and it’s impossible to take it to a
dealer before starting it, follow the steps described on page 92. Have
the vehicle serviced by your dealer at the first opportunity.

1

61

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. Not all obstacles are immediately visible.
Travel with caution in unfamiliar terrain.

62

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. 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. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter.
The override button should be used with caution as rearward vehicle
speed is greatly increased. Do not operate at wide open t hrottle. Open
the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.

63

OPERATION

Driving Safely

ParkingonanIncline

Avoid parking on an incline if possible. If it’s unavoidable, follow
these precautions:

1. Turn the engine off.

2. Place the transmission in park.

3. Set the parking brake.

4. Always block the rear wheels on the downhill side as shown.

64

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.

Spark Arrestor

Your Polaris ATV has a spark arrestor that was tested and approved in
accordance with the USDA Forestry Service Standard 5100-1C.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI
components are set at the factory for optimal performance and are not
adjustable.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter the atmosphere.

65

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance
schedule. Use the instrument cluster’s programmable service interval
mode to help determine when maintenance service is due. See page 45
for instructions.

Maintenance intervals are based upon average riding conditions and an
average vehicle speed of approximately 10 miles per hour. Vehicles
subjected to severe use, such as operation in wet or dusty areas, should
be inspected and serviced more frequently.

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.

NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a qualified dealer
perform these operations.

Maintenance Chart Key

" Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from
grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle)

J Dealer service item.

66

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at
20 hours, the equivalent odometer reading would be 200 miles.
Perform all services at whichever reading is reached first.

WARNING

Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Frequency Remarks

Brake System Pre-Ride Pre-Ride Inspect

Auxiliary Brake Pre-Ride Pre-Ride Inspect

Tires Pre-Ride Pre-Ride Inspect

Wheels Pre-Ride Pre-Ride Inspect

Frame nuts, bolts,
fasteners

Pre-Ride Pre-Ride Inspect

"

L

Air filter,
Pre-cleaner

Pre-Ride Pre-Ride Inspect; clean

Coolant level Pre-Ride Pre-Ride Replace coolant every two

years

Fuel tank and
engine oil

Pre-Ride Pre-Ride Fill to proper levels

Throttle Pre-Ride Pre-Ride Check operation

Lights Pre-Ride Pre-Ride Check operation

Engine stop switch Pre-Ride Pre-Ride Check operation

Steering Pre-Ride Pre-Ride Check for free operation

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

67

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

" Air box sediment

tube

Pre-Ride Pre-Ride Drain deposits whenever

visible

Headlamp Pre-Ride Pre-Ride Check operation daily; ap-

ply Polaris dielectric grease
to connector when replaced

Tail lamp/brake
lamp

Pre-Ride Pre-Ride Check operation daily; ap-

ply Polaris dielectric grease
to socket when replaced

"

L

Air filter,
main element

Weekly Weekly Inspect; replace as needed

" Transmission oil

level

20 hrs. Monthly Inspect monthly; change

annually

" Front and rear

gearcase oil

20 hrs. Monthly Check monthly; change

annually

Battery 20 hrs. Monthly Check terminals; clean;

check fluid level if applica­ble

"

L

Engine breather
filter

20 hrs. Monthly Inspect; replace annually

and as needed

J Brake pad wear 20 hrs. Monthly Inspect periodically

" General lubrication 50 hrs. 3 months Lubricate all fittings, pivots,

cables, etc.

68

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Frequency Remarks

"

L

Engine oil level/oil
change

100 hrs./
1000 mi.

6 months Check level daily; break-in

service at one month;
change oil more often in
cold weather

"

L

Oil Filter 100 hrs./

1000 mi.

6 months Replace with oil change

L

Engine breather
hose

100 hrs. 6 months Inspect

J Throttle Cable/ETC

Switch

50 hrs. 6 months Inspect; adjust; lubricate;

replace if necessary

J Drive belt 50 hrs. 6 months Inspect; replace as needed

" Steering 50 hrs. 6 months Inspect daily; lubricate

" Front suspension 50 hrs. 6 months Inspect; lubricate; tighten

fasteners

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners

" Drive chain(s) 50 hrs. 6 months Inspect daily; adjust and lu-

bricate if needed

" Rear axle 50 hrs. 6 months Inspect bearings; lube

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

69

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

Coolant strength 100 hrs. 12 months Inspect strength

seasonally; pressure test
system annually

L

Spark plugs 100 hrs. 12 months Inspect; replace as needed

J

L

Ignition Timing 100 hrs. 12 months Inspect; adjust as needed

J

L

Fuel system 100 hrs. 12 months Check for leaks at tank

cap, lines; replace lines
and filter every two years

Radiator 100 hrs. 12 months Inspect; clean external sur-

face

Cooling system
hoses

100 hrs. 12 months Inspect

J Clutches (drive and

driven)

100 hrs. 12 months Inspect; clean

Engine mounts 100 hrs. 12 months Inspect

J Brake fluid 200 hrs. 24 months Change every two years

J Fuel filter 200 hrs. 24 months Replace every two years

Spark arrestor 300 hrs. 36 months Clean out

J Front wheel bear-

ings

300 hrs. 36 months Inspect; replace as needed

L

Idle speed As required Adjust

J Toe adjustment As required Periodic inspection; adjust

when parts are replaced

Headlight aim As required Adjust as needed

70

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

10 hrs.

20 hrs.

50 hrs.

100 hrs.

71

MAINTENANCE AND LUBRICATION

Lubrication Guide

NOTE: Hours i n the frequency column are based on 10 mph average.
If service is due at 20 hours, the equivalent odometer reading would be
200 miles. Perform all services at whichever reading is reached first.

Lubrication Guide Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method Frequency

Engine Oil Polaris Premium 4

Synthetic 0W40

Add to proper level
on dipstick.

Check level daily.

Brake Fluid DOT 3 Only Maintain level

between fill lines.
See page 35.

As required; change every
two years or 200 hours

Transmission
Oil

Polaris AGL
Synthetic
Gearcase Lube

See page 75. Check every 6 mos./1000

miles. Change annually
or at 100 hrs.

Front
Gearcase Oil

Premium Hub
Drive Fluid

See page 76. Change annually

or at 100 hrs.

Rear
Gearcase Oil

ATV Angle Drive
Fluid (or GL5
80-90 weight gear
lube)

See page 77. Change annually

or at 100 hrs.

Front Prop
Shaft Yoke
(Fig. 1)

FGrease Grease fittings

(3 pumps maximum)

Every 3 months or 50 hrs.

Ball Joint
(Fig. 2)

"LGrease

Locate fitting on back
side of struts and
grease with grease
gun.

Every 3 months or 50 hrs.

(Fig. 1)

(Fig. 2)

72

MAINTENANCE AND LUBRICATION

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection. NOTE: See page 109 for the
part numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. (-40 to
+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. Oil may need to be changed m ore frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 synthetic oil or another 0W-40 API certified SH oil.
Never substitute or mix oil brands.

73

MAINTENANCE AND LUBRICATION

Oil Check

The oil dipstick and fill tube (1) are located on the left side of the
vehicle.

1. Position the ATV on a level surface.

2. Start the engine and let it idle for
20-30 seconds, then stop the
engine.

3. Lift the lever lock (2) to remove
the dipstick. Wipe it dry with a
clean cloth.

4. Reinstall the dipstick completely,
but do not lock it. The dipstick
must be screwed completely in to
keep the angle and depth of the
stick consistent.

5. Remove the dipstick
and check the oil level.
Maintain the oil level
in the safe range (3).
Do not overfill.
NOTE: Due to the
dipstick entry angle into
the crankcase, the oil level
will read higher on the
bottom side of the dipstick.
Always read the level on the
upper surface (4) of the dipstick.

6. After reinstalling the dipstick, be
sure to seat the lever lock.

1

SAFE

ADD 8 OZ

2

3

4

74

MAINTENANCE AND LUBRICATION

Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or
every six months, whichever comes first. Suggested break-in oil
change is at 20 hours, 200 miles, or one month, whichever comes first.
Severe use operation requires more frequent service. Severe use
includes continuous duty in dusty or wet conditions and cold weather
riding. NOTE: Severe use cold weather riding is all riding below 10°
F., and riding between 10° F and 30° F when most trips are slow speed
and less than five miles. Be sure to change the oil filter whenever
changing the oil.

Oil Change

1. Place the vehicle on a level surface.

2. Run t he engine for t wo to three minutes until warm. Stop the
engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase and remove the drain
plug.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to touch
skin.

5. Allow the oil to drain completely.

6. Replace the sealing washer on the drain plug. NOTE: The sealing
surfaces on drain plug and crankcase should be clean and free of
burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter counterclockwise to remove.

9. Using a clean dry cloth, clean the filter sealing surface on the
crankcase.

10. Lubricate the o-ring on the new filter with a film of fresh engine
oil. Check to make sure the o-ring is in good condition.

11. Install the new filter and turn by hand until the filter gasket
contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of
recommended oil.

13. Place the gear selector in park and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the
engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

75

MAINTENANCE AND LUBRICATION

Transmission Oil

The transmission oil level should be checked every six months or 1000
miles (1600 km), whichever comes first. Transmission oil should be
changed annually. We recommend the use of Polaris AGL Synthetic
Gearcase Lubricant. See page 109 for the part numbers of Polaris
products.

Oil Check

The transmission oil fill plug (1) is located on the right side of the ATV
behind the footwell.

1. To access the fill plug, remove
the four screws on the footwell
and gently pull outward to
remove the footwell.

2. Remove the fill plug and check
the oil level. Maintain the oil at
the bottom of the fill hole
threads.

Oil Change

3. Remove the transmission drain
plug (2). Drain the oil into a
drain pan and dispose of properly.

4. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

5. Remove the fill plug and add 13.5 oz. (399 ml) of the
recommended transmission oil. Maintain the level at the bottom of
the fill hole threads.

6. Replace the fill plug and check for leaks.

7. Reinstall the footwell and screws.

1

2

76

MAINTENANCE AND LUBRICATION

Front Gearcase Oil

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. We recommend the use of Polaris
Premium Hub Drive Fluid. See page 109 for the part numbers of Polaris
products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug (1) and view the
oil level. Maintain the oil level at the
bottom of the fill hole threads.

3. Add the recommended gearcase oil as
needed.

Oil Change

1. Position the vehicle on a level surface
and remove the fill plug.

2. Place a drain pan beneath the gearcase, remove the gearcase drain
plug located on the bottom right-hand side, and drain the oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 5 ounces (150 ml) of Polaris

Premium Hub Drive Fluid.

Maintain the oil level at the bottom of the fill hole threads.

5. Reinstall the fill plug and check for leaks.

1

77

MAINTENANCE AND LUBRICATION

Rear Gearcase Oil

The rear gearcase lubricant level should be checked every six months
or 1000 miles (1600 km), whichever comes first. Rear gearcase oil
should be changed annually. Use Polaris AGL Synthetic Gearcase
Lube (or GL5 80-90 weight gear lube). NOTE: See page 109 for t he
part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug and inspect the oil level t hrough the fill plug
hole (1). Maintain the oil level even with the bottom of the fill plug
hole.

3. Add the recommended gearcase oil as needed.

Oil Change

1. Place a drain pan beneath the drain
and remove the drain plug (2).
Catch and discard used oil properly.

2. Clean and reinstall the drain plug
with a new sealing washer. Torque
to 14 ft. lbs. (19 Nm).

3. Remove the fill plug and add 5
ounces (150 ml) of the recommended
gearcase oil.

4. Inspect the oil level, which should be
maintained level with the bottom of the fill plug hole.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm) and check for
leaks.

1

2

78

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the
left side of the machine. To access the
recovery bottle, remove the left side panel
as outlined on page 83.

The fluid level must be maintained
between the minimum and maximum
marks on the bottle (when the fluid is
cool).

The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the recovery bottle,
radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the recovery bottle. As engine coolant temperature decreases, t he
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.

NOTE: Some coolant level drop on new machines is normal, as the
system is purging itself of trapped air. Observe coolant levels and
maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40
anti-freeze/coolant or a 50/50 mixture of high quality aluminum
compatible anti-freeze/coolant and distilled water. See page 109 for the
part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.
Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.

1

79

MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the
pressure cap while the engine is warm or hot. Always allow the
engine to cool before removing the pressure cap.

Radiator Coolant Level

NOTE: This procedure is required
only if the cooling system has been
drained for maintenance and/or repair.
However, if the recovery bottle has
run dry, the level in the radiator
should be inspected and coolant
added if necessary .

1. Using the tool provided, remove
the four screws securing the front
rack (1). Remove the front cover (2) by placing your fingers under
the front of the cover and pulling upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add coolant as necessary through the
radiator filler neck.

4. Replace the pressure cap and secure the front cover and rack.

NOTE: Use of a non-standard pressure cap will not allow the
recovery system to function properly. Contact your dealer for the
correct replacement part.

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. Polaris Premium 60/40 is already premixed and
ready to use. Do not dilute with water. See page 109 for the part
numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.

2

1

80

MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever t oward the handlebar. These brakes are
self-adjusting.

The following checks are recommended to keep the brake system in
good operating condition. Check more often i f brakes are used heavily
under normal operation.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury. After opening a bottle of brake fluid,
always discard any unused portion.

1. Always keep brake fluid at an adequate level (see page 35).

WARNING

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. Do not overfill.

NOTE: 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. Always fill the reservoir as needed whenever the cover is
loosened or removed to ensure proper diaphragm operation. Use
Polaris DOT 3 brake fluid. Do not overfill.

81

MAINTENANCE AND LUBRICATION

Brakes

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or
spongy feel.

4. Check the friction pads for wear,
damage and looseness.

5. Check the security and surface
condition of the disc.

NOTE: Pads should be changed when
worn to 3/64″ (.1 cm), or about the
thickness of a U.S. dime.

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, the rear brake can be
activated by depressing the foot pedal on the inside of the right
footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as the
all-wheel single lever system.

3/64″ (.1 cm)

82

MAINTENANCE AND LUBRICATION

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod
adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a
straight-ahead position.
NOTE: The steering frog
can be used as an indicator
of whether the handlebars are
straight. The frog should
always point straight back
from the steering post.

2. Place stands (1) in front of
the vehicle, perpendicular to
the rear tires. See
illustration.

3. Tie an elastic string around
the stands, making sure t he
string just touches the side
surface of the rear tires on
each side of the vehicle and
goes around the stands in
front of the vehicle (2).

4. Measure the distance from
the string to the rim at the
front and rear of the front
rim (3). Rear measurement should be 1/16″ -1/8″ (.2to.3cm)
more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer
for service.

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.

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83

MAINTENANCE AND LUBRICATION

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.

2. Grasp the rear of the side
panel near the rear cab. With
a quick and firm motion, pull
the panel forward and outward
to disengage the two rear tabs.

3. Place your hand on top of the
side panel behind the fuel
tank. With a quick and firm
motion, push down on the side
panel to disengage the top rear
twotabs. Thenpulluponthe
side panel to disengage the
front upper and lower tabs.

4. To reinstall the side panel,
align the panel tabs with the
slots on the front cab. Push
the panel upward and forward
until the tabs lock. Bend the
rear of the side panel and
insert the t wo tabs into the rear
cab.

Step 2

Step 3

Step 4

84

MAINTENANCE AND LUBRICATION

WARNING

Operating your ATV 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
ATV and in the owner’s manual.

Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Tire Tread Depth

Always replace tires when tread
depth is worn to 1/8″ (.3 cm) or less.
See illustration.

Wheel Removal

1. Stop the engine, place the transmission in
park 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.

1/8I (.3 cm)

85

MAINTENANCE AND LUBRICATION

Wheel Installation

1. Place the transmission in park
and lock the parking brake.

2. Place the wheel on the
wheel hub with the valve stem
toward the outside and
rotation arrows on the tire
pointing toward forward
rotation.

3. Install the wheel nuts and finger
tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts according to the wheel nut torque
specifications chart.

NOTE: All nuts that have a cotter pin installed must be serviced by an
authorized Polaris dealer.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.

Bolt Size Sportsman 700

Front 3/8″ 30 ft. lbs. (41 Nm)

Rear 3/8″ 30 ft. lbs. (41 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.

86

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the
air box cover clips, and
remove the air box cover.

2. Loosen the clamp and remove
the filter.

3. Remove the fabric type
pre-filter (1) from the main
filter (2). Wash the pre-filter
in soapy water, then rinse and
let dry.

4. Reinstall the pre-filter over t he
main filter. (Replace the main
filter if needed.)

5. Reinstall the filter into the air box and tighten the clamp. Do not
over tighten the clamp, as filter damage could occur.

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. To access the breather filter (3), remove the left side panel as
outlined on page 83. The breather filter is on the hose that runs
between the engine and air box.

2. Remove the clamps and pull the filter out of the hoses.
NOTE: It’s not necessary to remove the lower hose from the
engine.

3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace if needed.

4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.

5. Reinstall the filter and secure the clamps.
NOTE: The filter is effective with the arrow pointing in either
direction.

CAUTION

Operation of your vehicle without a breather filter can cause
engine damage. Always reinstall the breather filter after removing
for service.

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87

MAINTENANCE AND LUBRICATION

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.

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 .

Headlight Lamp Replacement

1. Remove the two screws on the lower front corners of the headlight
pod.

2. Using a small flat-blade screwdriver , push in on the lock tab
through the two small openings at the front of the headlight pod.

3. Lift the pod slightly while depressing the tabs.

4. Remove the screw in the back of the headlight pod.

5. Lift the pod cover and disconnect the speedometer harnesses from
the speedometer. Unplug the indicator light harness and remove
the pod cover.

6. Unplug the headlamp from the wiring harness. Be sure to pull on
the connector, not on the wiring.

7. Remove the boot and locking collar from the back of the lamp
housing.

8. Grasp the base of the lamp and lift it out.

9. Reverse the previous steps to replace the lamp and reassemble the
pod. Apply dielectric grease to the light bulb socket before
installing the new bulb. Make sure the tab on the lamp locates
properly in the housing.

88

MAINTENANCE AND LUBRICATION

Lights

High Bea m 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. Position the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.

3. Start the engine and t urn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of
the headlight beam should be aimed two inches (5.1 cm) below the
mark placed on the wall. NOTE: Include rider weight on the seat
when measuring.

5. Adjust the beam to the desired position by turning the adjustment
knob either clockwise or counterclockwise.

Snap pins
into tabs

Position
knob in
slot and
secure in
locking
tabs

Adjustment
Knob Stop

Route plug
over handlebar

89

MAINTENANCE AND LUBRICATION

Lights

Headlight Housin g Replacement

1. Remove the two screws on the lower front corners of the headlight
pod.

2. Using a small flat-blade screwdriver , push in on the lock tab
through the two small openings at the front of the headlight pod.

3. Lift the pod slightly while depressing the tabs.

4. Remove the screw in the back of the
headlight pod.

5. Lift the pod cover. Disconnect the
speedometer harnesses from the
speedometer. Unplug the indicator
light harness and remove the pod cover.

6. Unplug the headlamp from the wiring
harness.

7. Pull the headlight housing up to
release from the locking tabs.

8. Lift the adjusting knob up to remove
from the locking tabs.

9. Carefully pull the assembly up and out of pod.

10. Reverse the steps to install the new housing and reassemble the
pod.

NOTE: The distance from the headlamp parting line to the end of the
adjustment knob stop is 5 1/8″ (13 cm). See illustration.

11. Adjust the headlight aim by turning the adjusting knob.

51/8″
(13 cm)

90

MAINTENANCE AND LUBRICATION

Lights

Lower Headlamp Removal / Installation

1. Turn the back of the headlight harness (1) in a
counterclockwise direction.

2. Pull the harness assembly out from the headlight
assembly.

3. Remove the headlamp and replace with a
new headlamp.

4. Install the new headlamp and harness assembly
into the headlight assembly. Turn the headlight harness
clockwise to secure the headlamp in place.

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.

2. Remove the lamp (3) and
replace it with a new lamp.

3. Test the taillight/brakelight to
see that it’s working.

4. Reinstall the gasket and lens cover.

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91

MAINTENANCE AND LUBRICATION

Spark Plugs

S Use RC7YC spark plugs.
S Proper electrode gap is .035″ (.90 mm).
S Spark plug torque is 18 ft. lbs. (24 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. Immediately
check the spark plugs for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.

1. Normal

The normal insulator tip is gray, t an or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be flaky and white. A white insulator tip
indicates overheating, caused by use of an improper spark plug or
incorrect fuel.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, t he
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended oil or incorrect throttle body adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 18 ft.
lbs. (24 Nm).

92

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 t ake your ATV to a dealer before starting it, follow
the steps outlined below.

1. Move the ATV to dry l and or at the very least, to water below the
footrests.

2. Check the air box for any water and dry it if it’s wet.
NOTE: Filter replacement is required if water is present.

3. Remove the spark plugs.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs and reinstall, or replace with new plugs.

6. Attempt to start the engine. If necessary, repeat the drying
procedure.

7. Take the ATV to your dealer for service as soon as possible,
whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure
on page 95 for drying out the PVT.

93

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.

Remove any combustible materials from the area. Wear eye
protection and leather work gloves. Do not stand behind or in
front of the vehicle while purging. Never run the engine in an
enclosed area. Exhaust contains poisonous carbon monoxide
gas. Never go under the vehicle while it’s inclined.

Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.

1. Remove the arrestor clean-out
plug (1) from the bottom of the
muffler.

2. Place the transmission in PARK
and start the engine.

3. Purge carbon from t he system by
momentarily revving the engine
several times.

4. If carbon is expelled, cover or plug the
exhaust outlet (2) and rap on the pipe around
the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Set the parking brake
and block the wheels. Make sure the vehicle is in PARK and
repeat steps 3 and 4 until no more particles are expelled when the
engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the
arrestor plug and remove the outlet cover or plug.

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94

MAINTENANCE AND LUBRICATION

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, i ncreases the amount of pinch appliedtothe
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt pinch.

On Polaris ATVs, the approximate gear ratio difference between high
and low range is 1:2.25. This difference in gearing affects the operation
of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the
system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 KPH) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1200 - 1400 RPM. However, in high
range at 3 MPH (5 KPH), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed
to prevent belt slip. B elt slip is responsible for creating the excessive
heat that destroys belts, wears clutch components and causes outer
clutch covers to fail.

By switching to low range while operating at low ground speeds, the
air temperature in the clutch cover is reduced by almost 160 degrees.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).

When To Use Low Range vs. High Range

Following is a guideline for when to use low range and high range.

Low Range

S When basic operation is at speeds less than 7 MPH (11 KPH)
S For heavy pulling
S When operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

S When basic operation is at speeds greater than 7 MPH (11 KPH)
S When operating at high ground speeds

95

MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result in
severe injury or death.

Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.

The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner , you have the following responsibilities to
make sure this system remains safe:

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.

PVT Drying

There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:

1. Remove the drain plug and allow the water to drain. Replace the
drain plug.

2. Start the engine and shift the transmission into park. Apply varying
throttle for 10-15 seconds to expel the moisture and air-dry the belt
and clutches. Do not hold the throttle wide open for more than 10
seconds.

3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

96

MAINTENANCE AND LUBRICATION

Battery

WARNING

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. Disconnect the battery hold-down strap.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Lift the battery out of the ATV.

Battery Installation

When installing a new battery, make sure it’s fully charged prior to its
initial use. Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also hinder
vehicle performance. Follow the battery charging instructions on page
97 before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Attach the hold-down strap.

6. Verify that cables are properly routed.

97

MAINTENANCE AND LUBRICATION

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a month to
make up for normal self-discharge. B attery Tendert can be left
connected during the storage period, and will automatically charge the
battery if the voltage drops below a pre-determined point.

Battery Charging

The following battery charging instructions apply only to the
installation of a YUASA activated, sealed battery. Read all
instructions before proceeding with the installation of this battery.

The YUASA activated, sealed battery is already filled with electrolyte
and has been sealed and fully charged at the factory. Do not ever pry
the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is
to keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until thebattery voltage is 12.8 or greater.

NOTE: When using an automatic charger, refer to the charger
manufacturer’s instructions for recharging. When using a constant
current charger, use the following guidelines for recharging.

WARNING

An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the
battery becomes very warm to the touch. Allow it to cool before
resuming charging.