Polaris 2009 Trail Boss 330 Owner's Manual

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9921784 Rev 02
Printed in USA

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 1-800-342­3764 for assistance.

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

1

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of 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 complete line of apparel, parts and acces­sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus­tries Inc.

Copyright 2008 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 in acc uracies. 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.
2009 Trail Boss Owner’s Manual
P/N 9921784

3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Emission Control Systems . . . . . . . . . . . . . . . 56

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 103

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 104

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 108

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 116

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

4

INTRODUCTION

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 indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5

INTRODUCTION

Failure to heed the warnings and safety precautions 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris ATV. Keep this manual with
the ATV.

• Never operate an ATV without proper instruction. Take a training course.
Purchasers of a new Polaris ATV and their eligible family members are
entitled to take the ATV RiderCourse

sm

. Contact ATV Enrollment Express at
[phone] or visit www.atvsafety .org for information on enrollment in the
ATV RiderCoursesm.

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

• 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.

WARNING

6

INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)

Key Number: ___________________________________________________________

####

VIN

Key Number

7

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. When you purchased
your new ATV, your dealer instructed you on the authorized ATV

RiderCourse

sm

available to you and your eligible family members. This
training is included in the purchase price of your ATV. Polaris strongly
encourages you and your eligible family members who will be riding
the ATV to take the ATV RiderCourse

sm

. 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, you can take the ATV

RiderCourse

sm

by calling ATV Enrollment Express at [phone] or
by visiting www .atvsafety.org. Purchasers of a used Polaris ATV will be
charged for this training.

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

W e 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.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the
Consumer Product Safety Commission at 1-800-638-2772, or visit
www.cpsc.gov, visit www.atvsafety .org, or call Polaris at 1-800 -342-

3764.

8

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of
Transportati on (DOT) label.

Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When­ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

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

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

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.

Equipment Modifications

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.

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.

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.

10

SAFETY

Safety W arnings

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.

Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.

Never permit a guest to operate the AT V unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.

Age Restrictions

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

Even though a child may be within the
recommended age group for operating some A TVs,
he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and
could be susceptible to accident or injury.

WARNING

11

SAFETY

Safety W arnings

Handling Gasoline

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 refu-

eling 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.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.

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.

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.

Always inspect the ATV before each use to make
sure it's in safe operating condition.

Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.

12

SAFETY

Safety W arnings

Protective Apparel

Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.

Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).

Using Alcohol or Drugs

Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.

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

Carrying a Passenger

Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.

Never carry a passenger on this ATV.

13

SAFETY

Safety W arnings

Operating on Pavement

Operating an A TV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.

Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.

Never operate the A TV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.

Operating at Excessive
Speeds

Operating the ATV at excessive speeds
increases the operator's risk of losing
control.

Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.

14

SAFETY

Safety W arnings

Physical Control of the ATV

Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.

Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of
traction, loss of control, accident or overturn.

Always follow proper procedures for turning
as described in the owner's manual.

Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.

Jumps and Stunts

Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.

Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 46.

15

SAFETY

Safety W arnings

Descending Hills Improperly

Improperly descending a hill could cause loss
of control or overturn.

• Always follow proper procedures for travel-

ing down hills as describe d in th e ow ner's
manual. NOTE: A special technique is
required when braking while traveling down­hill. See page 48.

• Always descend a hill with the transmission

in forward gear. Do not descend a hill with
the transmission in neutral.

• Always check the terrain carefully before

descending a hill.

• Shift your weight rearward.

• 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.

Crossing Hillsides

Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 47.

Never attempt to turn the ATV around on any hill
until you've mastered the turning technique (on
level ground) as described in the owner's
manual. See page 49.

16

SAFETY

Safety W arnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.

• Always maintain a steady speed when climbing
a hill.

If all forward speed is lost:

• Keep body weight uphill.

• Appl y the single-lever brake gradually.

• Lock the parking brake when fully stopped.

• 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 49.

If the AT V begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the auxiliary rear brake while rolling backwards. Apply the single­lever brake gradually.

• When fu lly 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 49.

Operating on Steep Hills

Operating on excessively steep hills could cause
an overturn.

Never operate on hills too steep for the AT V or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.

17

SAFETY

Safety W arnings

Operating on Slippery Terrain

Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.

Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.

Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control or
overturn.

Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.

18

SAFETY

Safety W arnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 52.

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

Improper Tire Maintenance

Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.

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

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

19

SAFETY

Safety W arnings

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 51.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.

Operating Through Deep Water

Operating the ATV through deep or fast­flowing water could cause the tires to float,
causing loss of control or overturn.

Avoid operating the A TV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page

50):

• Travel slowly.

• Balance your weig ht carefully.

• Avoid sudden movements.

• 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. After leaving water, test the

brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.

20

SAFETY

Safety W arnings

Improper Cargo Loading

Overloading the A TV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.

• 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.

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the
ATV and /or the operator fall through the ice.

Never operate the ATV on a frozen body of water.

Poor Visibility

Operating the A TV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.

21

SAFETY

Safety W arnings

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. 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.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabiliti es who operate this vehicle
have an increased risk of overturn and loss of control.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.

22

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, con­tact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.

General Warning

WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk
of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough ter­rain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

23

SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-

vent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.

• REVERSE operation can be dangerous even at low speeds. Steering

becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.

7175511

Rack Warning, Front and Rear

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

• Max Rack Loads: Front 75 lb s. (34 kg) Rear 125 lbs. (57 kg)

7172666

+

General

Warning

+

Discretionary

Warning

Rack Warning

+

+

Rack Warning

24

SAFETY

Safety Labels and Locations

“No Passenger” Warning

WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Tire Pressure/Load Warning

WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa)
Rear: 3.0 psi (20.7 kPa)

• Maximum weig ht capacity: 415 lbs. (188 kg)

7175444

+

“No Passenger”

Warning

+

Clutch Cover

Warning

+

Age 16 Warning

+

Tire Pressure/Load

Warning

25

SAFETY

Safety Labels and Locations

Age 16 Warning

WARNING
Operating this A TV if you are under the age of 16 increases your chance of

severe injury or death.
NEVER operate this ATV if you are under age 16.

7175374

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or
death.

NO STEP

7172563

Reverse Override Warning

WARNING
Improper use of override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.

7175486

26

FEATURES AND CONTROLS

Switches

Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and press the
override switch.

WARNING! Pressing the override switch while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override switch.

The override switch also allows activation of All Wheel Drive in
reverse, if the AWD switch is on.

Engine Stop Switch

Move the stop switch either left or right to
the OFF position to stop the engine
quickly. The engine will not start or run
when the switch is off.

Both the main switch and the engine stop
switch will shut off all el ectrical power to
the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 41 for starting pro­cedures.

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight Switch

OFF OFFRUN

27

FEATURES AND CONTROLS

Switches

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam (if equipped). The key must be in the
ON position and the engine stop switch must be in the RUN position to
operate the headlights.

Indicator Lights

With the en gine running, verify the function of all indicator lights before
each use of the vehicle.

Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to

prevent battery drain.

Neutral Indicator

Reverse Indicator

High Temperature Warning

(displays if engine overheats)

28

FEATURES AND CONTROLS

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.

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.

Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.

Engine speed and vehicle move­ment are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.

This ATV is equipped with Polaris
Electronic Throttle Control (ETC),
which is designed to reduce the risk
of a frozen or stuck throttle. If the
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

29

FEATURES AND CONTROLS

Brake Lever

Operating the A TV 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. Always contact your dealer for service before operating the vehicle.

Squeeze the brake lever toward the handlebar to apply the front and rear
brakes. These brakes are hydraulically activated disc type brakes that
are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before
riding. 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 yo ur dealer for proper
diagnosis and repairs.

Parking Brake

Locking the Parking Brake

1. Place the transmission in gear.

2. Squeeze and release the brake

lever two or three times, then
squeeze and hold.

3. Push the parking brake lock for-

ward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.

The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. 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. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.

WARNING

30

FEATURES AND CONTROLS

Auxiliary Foot Brake

Aggressively applying the auxiliary brake when backing down a hill may cause
rear tipover, which could result in serious injury or death. Never back down a hill.

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, which may result in serious injury or death.

The auxiliary brake system is
intended to be used as a
backup for the main brake sys­tem. Should the main system
fail, use the auxiliary foot
brake.

The auxiliary foot brake is
located on the inside of the
right footrest. Operate this
brake with your right foot.

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

WARNING

Auxiliary

Foot Brake

31

FEATURES AND CONTROLS

Brake Fluid

An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.

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 brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.

Always maintain brake fluid at the recommended level. Do not overfill.
If the fluid level is low add DOT 4 brake fluid only . See page 103 for the
part numbers of Polaris products.

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. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.

WARNING

32

FEATURES AND CONTROLS

Brake Fluid

Hand Brake

Check the brake fluid level in the
master cylinder before each use of
the vehicle. The master cyl inder is
located on the left handlebar.
Maintain the fluid level 1/4" (6
mm) below the top edge of the
master cylinder. Do not overfill.

1. Position the vehicle on a level

surface. Make sure the han­dlebars are straight.

2. View the fluid level through

the indicator window (eye) on
the top of the master cylinder. The eye will appear dark when the
fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended fluid as needed. Do not overfill.

Auxiliary Foot Brake

Check the brake fluid level frequently for the auxiliary brake system.
The brake fluid reservoir is located either under the seat or near the foot
brake. Maintain the fluid level between the minimum and maximum
marks. Do not overfill.

Master Cylinder

Indicator

Window

33

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 41 for correct choke and throttle settings during start­ing.

Fuel Tank Cap

Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level sur­face.

Remove the fuel tank cap to add fuel
to the fuel tank. Use either leaded or
unleaded gasoline with a minimum
pump octane number of 87=(R+ M/2)
octane. Do not use E-85 fuel.

Fuel Valve

The fuel valve is located on the left
side of the vehicle, below the fender.

ON: For normal operation.
OFF: For vehicle storage and when

transporting.
RES: Turn the valve to the reserve set-

ting if the main fuel supply is
exhausted. Refuel as soon as possible.
Return the valve to the ON position
after refueling.

Reserve fuel range is about 7-10 miles
(11-16 km).

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100
hours of operation or annually. Do not attempt to clean the fuel filter.

Fuel Tank

Cap

Fuel

Valve

OFF

ON

RES

34

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

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

F: Forward Gear
N: Neutral
R: Reverse

To shift gears, brake to a complete stop.
When the engine is idling, move the lever
to the desired gear.

NOTICE: Shifting gears with the engine

speed above idle or while the
vehicle is moving could cause
transmission damage.

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

Gear

Selector

35

FEATURES AND CONTROLS

Recoil Starter

If the battery is too weak to start
the engine, use the recoil starter.
Follow the starting procedures on
page 41, cranking the engine with
the recoil starter instead of the
main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slowly so you can feel the

engine strokes.

Tip: The rope will be harder to pull when the engine is on a compression stroke.

When a compression stroke is found, continue pulling the rope just until the
engine rolls past the stroke, then stop pulling immediately.

3. Allow the recoil rope to rewind into the recoil assembly, then pull

the rope abruptly and forcefully to start the engine.

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

NOTICE: Extending the recoil starter rope until it stops can cause damage to

the recoil assembly. Do not extend the starter rope so far that it stops.
If the starter rope handle is not seated properly, water may enter the

recoil housing and damage components. Make sure the handle is
fully seated on the recoil housing, especially when traveling in wet
areas.

Recoil Starter

Handle

36

OPERATION

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.

Break-In Period

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

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.

WARNING

37

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 33. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level on the dipstick. See page 62. Add oil if neces-

sary to maintain the level in the safe operating range.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize 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 40.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours or one month, which-

ever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur­ing the break-in period.

38

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to oper­ate this vehicle.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Before operating, learn how to use the auxiliary brake for emer-

gency situations (if service brakes become inoperable).

6. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt
and gravel roads.

7. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights fre­quently and replace burned out headlamps promptly.

8. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handle­bars while operating, and always keep both feet on the footrests.

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

10. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

11. Never operate a damaged ATV. After any overturn or accident, have

a qualified service dealer inspect the entire machine for possible
damage.

12. Never operate the ATV on a frozen body of water.

13. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

14. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

39

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con­tacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow . Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles opera ting in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, mo ve your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

40

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 29

66

Brake fluid Ensure proper level 31

Auxiliary brake Ensure proper operation 30

Front suspension Inspect, lubricate if necessary 61

Rear suspension Inspect, lubricate if necessary 61

Steering Ensure free operation -

Tires Inspect condition and pressure 71

Wheels/fasteners Inspect, ensure fastener tightness 71

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 33

62

Throttle Ensure proper operation 28

69

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 26

Drive chain Check condition/slack, lubricate as

needed

77

Air filter, pre-filter Inspect, clean 74

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

27
81

Brake light/tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

82

Riding gear Wear approved helmet, goggles, and

protective clothing

8

41

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti-

lated area.

2. Place the transmission in neutral.

3. Lock the parking brake.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

Tip: Do not us e th e choke if starting a warm engine. Excessive use of the choke

can cause the spark plug to become wet fouled.

6. If the engine is cold, pull the

choke knob out until it stops.
If the knob doesn't stay where
positioned, increase the ten­sion by rotating the tension
adjusting nut clockwise.

Tip: The variable choke is fully on

when the knob is pulled com­pletely out. The choke is off when
the knob is pushed completely in.
The choke can be adjusted gradu­ally, depending on how much
choke is needed for starting. Be
sure the choke is off during opera­tion, as excess fuel washing into
the engine oil will increase wear
on engine components.

7. Move the engine stop switch to RUN.

8. Do not press the throttle while starting the engine.

Choke

Knob

Adjusting

Nut

42

OPERATION

Starting the Engine

9. 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 engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

damage. Allow the engine to warm up for several minutes before
operating the vehicle.

10. If the engine does not start, return the key to the OFF position and

wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repea t this procedure
until the engine starts.

Tip: If a warm engine has cooled to a point where it does not readily start, inter-

mittent use of the choke (knob pulled half way out) may be necessary . If the
engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. Release the throttle lever immediately after the
engine starts. If the engine does not start and all conditions are favorable,
change the spark plug and try again.

11. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.

43

OPERATION

Driving Procedures

1. Wear a helmet and eye protection. See page 8.

2. Sit upright with both feet on the footrests and both hands on the

handlebars.

3. Start the engine and allow it to warm up.

4. Shift the transmission into gear.

5. Check your surroundings and determine your path of travel.

6. Release the parking brake.

7. Slowly depress the throttle with your right thumb and begin driving.

8. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

44

OPERATION

Turning the Vehicle

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.

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

WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.

45

OPERATION

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

3. Engage AWD before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if AWD is engaged while the

wheels are spinning. Allow the rear wheels to stop spinning before
engaging AWD, or engage AWD before wheels begin to lose traction.

4. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

5. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body
weight forward.

Sideways

skid

Turn in

direction of

skid

46

OPERATION

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter­rain. Improper procedure could cause loss of control or overturn. When­ever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

3. Always check the terrain carefully before ascending any hill.

4. Never climb hills with excessively slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

8. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

25° Maximum

47

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

5. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

48

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Shift body weight uphill.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause

loss of control.

5. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of con­trol.

49

OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.

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 vehi-

cle is pointing straight uphill.

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

5. While holding the brake lever, 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. Remount the vehicle from the uphill side,

keeping body weight uphill.

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

8. Release the parking brake and proceed slowly, controlling speed

with the brake lever, until the vehicle is on more level ground.

8 ft. (2.4 m)

50

OPERATION

Driving Through Water

Your ATV can operate
through water with a maxi­mum recommended depth
equal to the bottom of the
footrests. Follow these pro­cedures when operating

through water:

1. Determine water

depths and current
before entering water.

2. Choose a crossing

where both banks have
gradual inclines.

3. Avoid operating

through deep or fast-flowing water.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 57. The following areas need
special attention: engine oil, transmission oil, front and rear
gearcases (if equipped) and all grease fittings

.

If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 85,
then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several

times while driving slowly. The friction will help dry out the pads.

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid su dd en movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.

Maximum Depth

51

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

52

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.

NOTICE: 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.

53

OPERATION

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

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

5. Turn the fuel valve off.

54

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:

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

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.

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 only one rack
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 OPERAT ING. 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 poin t
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 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.

WARNING

55

OPERATION

Hauling Cargo

Never exceed the weight
capacities specified for your
ATV on warning labels and in
the specifications section of
this manual.

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.

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.

• The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity.

• The total load (operator , accessories, car go and weigh t on hitch) must

not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or

exceeding the maximum tongue
weight capacity can result in
serious damage to the vehicle and
will void your ATV warranty. Never
install a hitch longer than 4" (10
cm). Never install automotive
accessories on your Polaris ATV.
Always install Polaris-approved (or
equivalent) accessories designed
for ATV use.

1/3

2/3

Maximum

4" (10 cm)

56

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to
be in accordance with the USDA Forest Service Standard 5100-1C. Fed­eral law requires that this spark arrestor be installed and functional when
the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Fed­eral regulations can be viewed online at www.gpoaccess.gov/ecfr/.

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. All
exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine and
related components must be maintained at Polaris specifications to
achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed by an
authorized Polaris dealer .

The vehicle compliance labels can be found on the frame tubing of the
vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

57

MAINTENANCE

Periodic Maintenance Chart

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 ch art .

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on
page 116.

Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour (16 km/h). Vehicles subjected to severe use must be
inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crank­case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.

58

MAINTENANCE

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to

severe use.

E Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

WARNING

59

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Q

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist
on page 40.

X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride -
X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -
XEAir filter, pre-filter - Daily - Inspect; clean often; replace

as needed

X Air box sediment

tube

- Daily - Drain deposits when visible

Headlamp/tail
lamp

- Daily - Check operation; apply
dielectric grease if replacing

XEAir filter,

main element

- Weekly - Inspect; replace as needed

Recoil housing
(if applicable)

- Weekly - Drain water as needed,
check often if operating in wet
conditions

X

Q

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
XEEngine breather

filter (if equipped)

25 H Monthly 250 (400) Inspect; clean if needed

X General

lubrication

50 H 3 M 500 (800) Lubricate all fittings, pivots,

cables, etc.

Carburetor float
bowl

50 H 6 M 500 (800) Drain bowl periodically and

prior to storage

Q

E

Throttle Cable/
ETC Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

Q

E

Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

60

MAINTENANCE

Periodic Maintenance Chart

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

E Carburetor air

intake ducts/flange

50 H 6 M 500 (800 Inspect duct for proper seal-

ing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

needed

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

at 20 hours

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

Q

E

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

Q

E

Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,
carburetor; replace lines
every two years

X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

Q

E

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Q

E

Ignition Timing 100 H 12 M 1000 (1600) Inspect

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

security; apply dielectric
grease to connectors
subjected to water, mud, etc.

Q

Clutches (drive
and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn

parts

Q

Front wheel
bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

Q

Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Idle speed - Adjust as needed

Q

Toe adjustment - Inspect periodically; adjust

when parts are replaced

Headlight aim - Adjust as needed

61

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 57. Items not listed in the
chart should be lubricated at the General Lubrication interval. See page
103 for the part numbers of Polaris products.

The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However , if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.

Item Lube Method

Engine Oil PS-4 PLUS Performance

Synthetic 2W-50

See page 62.

Brake Fluid DOT 4 Only See page 31.

Drive Chain(s) O-ring chain lube or SAE

80/90

Lubricate.

Transmission Oil AGL Synthetic Gearcase

Lube

See page 64.

Ball Joint XPremium All Season

Grease

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

Swing Arm
Bushings

XPremium All Season
Grease

Locate fittings on swing arm and
grease with grease gun

Axle Housing

Swing Arm

Bushings

Ball Joint

Axle

Housing

62

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn­thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to
be changed more frequently if Polaris oil is not used. Always use 2W -50
oil. Follow the manufacturer's recommendations for ambient tempera­ture operation.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute
or mix oil brands.

Oil Specifications

Oil Level

The oil dipstick is located on the left side of the vehicle.

1. Position the vehicle on a level surface. Place the transmission in
neutral. Lock the parking brake.

2. Start the engine. Allow it to idle for 30 seconds. Stop the engine.

3. Remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall the dipstick completely.

5. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

6. Reinstall the dipstick.

Lubricant Capacity Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

1.9 qts. (1.8 l) (with oil cooler)

1.7 qts. (1.6 l) (oil change only)

14 ft. lbs. (19 Nm)

{

Safe Range

Dipstick

63

MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 57. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface. Place the transmission in
neutral. Lock the parking brake.

2. Clean the area around the drain plug.

3. Start the engine. Allow it to idle for two to three minutes. Stop the

engine.

4. Place a drain pan under the engine crankcase. Remove the drain

plug. Allow the oil to drain completely.

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

5. Reinstall the drain plug with a new sealing washer. Torque to speci-

fication. See page 62.

Tip: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches.

6. Place towels under the oil filter. Using an oil filter wrench, turn the

filter counterclockwise to remove it.

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

crankcase.

8. Lubricate the gasket on the new filter with a film of new engine oil.

Check to make sure the gasket is in good condition.

9. Install the new filter and turn by hand until the filter gasket contacts

the sealing surface, then turn an additional 1/2 turn.

10. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the

recommended oil (see page 62). Reinstall the dipstick.

11. Start the engine and allow it to idle for one to two minutes. Stop the

engine and inspect for leaks.

12. Recheck the oil level and add oil as necessary to bring the level to

the upper mark on the dipstick.

13. Discard used oil and filter properly.

64

MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57. Polaris
recommends the use of Polaris Premium AGL Synthetic Gearcase Lube.
See page 103 for the part numbers of Polaris products.

Transmission Oil Recommendations

Oil Check

The dipstick is located on the right side of the vehicle near the recoil
handle.

1. Position the vehicle on a level
surface.

2. Remove the dipstick. Wipe it

dry with a clean cloth.

3. Reinstall the dipstick com-

pletely.

4. Remove the dipstick and check

the fluid level. Add fluid as
needed. Maintain the fluid
level in the safe range. Do not
overfill.

5. Reinstall the dipstick.

Gearcase Lubricant Capacity Drain Plug

To r q u e

Transmission Premium AGL Synthetic

Gearcase Lubricant

11.3 oz.

(335 ml)

14 ft. lbs.

(19 Nm)

Dipstick

65

MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level
surface.

2. Place a drain pan beneath the

transmission oil drain plug area.

3. Loosen the jam nut.

4. Turn the adjuster bolt in to allow

the removal of the drain plug.

5. Remove the drain plug and wipe

the magnetic end clean to
remove accumulated metallic
filings.

6. Allow the oil to drain com-

pletely.

7. Reinstall the drain plug with a

new sealing washer. Torque to
specification.

8. Turn the adjuster bolt out until it

touches the frame, and then turn
an additional 1/2 turn.

9. Tighten the jam nut securely while holding the adjuster bolt.

10. Add the recommended lubricant through the dipstick hole until the

oil level is between the upper and lower limits. Do not overfill.

11. Reinstall the dipstick.

12. Check for leaks.

Jam

Nut

Drain Plug

Adjuster

Bolt

66

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. The auxiliary foot brake is
also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

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

1. Always keep brake fluid at an
adequate level. See page 31.

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. Replace
the pads when the friction mate­rial is worn to 1 mm.

5. Check the security and surface

condition of the disc.

1 mm

67

MAINTENANCE

Side Panel Removal

Tip: 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 two tabs. Then
pull up on the 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 two tabs
into the rear cab.

Step 3

Step 2

Step 4

68

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

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.

1. Position the vehicle on a level surface.

2. Set the handlebars in a straight-ahead position and secure them in
this position.

3. Place a chalk mark on the
center line of the front tires
approximately 10" (25.4 cm)
from the floor, or as close to
the hub/axle center line as
possible. Make sure both
marks are the same distance
from the floor.

4. Measure the distance
between the marks and
record the measurement (1).

5. Move the vehicle until the
chalk marks are at the rear
of the tires, even with the
hub/axle center line.

6. Measure the distance between the marks and record the
measurement (2).

7. Subtract measurement 2 from measurement 1. The difference is the
vehicle toe-out alignment.

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

1

2

69

MAINTENANCE

Throttle Cable Freeplay

Adjust throttle cable freeplay at
the handlebar.

1. Locate the throttle cable
adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far
enough to expose the end of
the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the thumb lever.
While adjusting freeplay, be
sure to flip the throttle lever
back and forth.

5. T igh ten the lock nut.

6. Squeeze the end of the rub-

ber boot and slide it over the
cable adjuster to its original
position.

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.

Lock Nut

Adjuster

Boot

70

MAINTENANCE

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is
adjusted by rotating the adjuster either
clockwise or counterclockwise to
increase or decrease spring tension.

Accessory springs are available through
your Polaris dealer.

Handlebars

The handlebars can be adjusted for rider preference.

WARNING! Improper adjustment of the handlebars or incorrect torquing of the
adjuster block tightening bolts can cause limited steering or loose ning of the
handlebars, resulting in loss of control and serious injury or death. Follow the
adjustment procedures exactly, or see your Polaris dealer for service.

1. Remove the handlebar cover to
access the handlebar bolts.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the

desired height.

4. Be sure the handlebars do not

contact the gas tank or any other
part of the machine when turned
fully to the left or right.

5. Torque th e front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque

the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear
bolts.

Adjuster

Handlebar Bolts

71

MAINTENANCE

Tires

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. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 108 for recom­mended tire type, size and pressure.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 1/8" (3 mm) or
less.

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.

WARNING

1/8" (3 mm)

72

MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface. Place the transmission in
gear. Lock the parking brake.

2. Loosen the wheel nuts slightly.

WARNING! Do not service axle nuts that have a cotter pin installed. See your
Polaris dealer.

3. Place a suitable stand under the

footrest frame to raise the wheel
slightly off the ground.

4. Remove the wheel nuts.

5. Remove the wheel.

Wheel Installation

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

2. Install the wheel nuts finger tight.

On vehicles with tapered rear
wheel nuts, make sure the tapered
ends of the nuts fit into the tapers
on the wheels.

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to

specification (page 73).

WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued to
specification.

73

MAINTENANCE

Tires

Wheel Nut Torque Specifications

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

Item Torque Specification

Front Wheel Nuts 27 ft. lbs. (37 Nm)

Rear Wheel Nuts 50 ft. lbs. (68 Nm)

Rear

50 ft. lbs.

(68 Nm)

Front

27 ft. lbs.

(37 Nm)

74

MAINTENANCE

Air Filter

1. Position the vehicle on a level surface. Place the transmission in
gear. Lock the parking brake.

2. Remove the seat.

3. Release the air box cover clips,

and remove the air box cover.

4. Loosen the clamp and remove

the filter.

5. Remove the pre-filter from the

main filter.

6. Wash the pre-filter in soapy

water, then rinse and let dry.

7. Reinstall the pre-filter over the

main filter. Replace the main
filter if needed.

8. Reinstall the air filter into the

air box. T ighten the clam p, but
do not over-tighten as filter
damage could occur.

9. Reinstall the air box cover and the seat.

Pre-Filter

Main Filter

75

MAINTENANCE

Recoil Housing

Always drain the recoil housing after operating the vehicle in wet condi­tions. Drain the housing before storing the vehicle. Make sure the hous­ing is completely dry before reinstalling the drain plug.

Water will enter the recoil housing if the starter handle is disengaged
from the rope guide when under water.

1. Place the transmission in gear.

2. Lock the parking brake.

3. Stop the engine.

4. Remove the drain screw on the
bottom of the recoil housing.

5. Reinstall the drain screw.

Tip: Do not open the crankcase drain

unless the engine has ingested water.
On 4-cycle engines, some engine oil
will be lost if the crankcase drain is
opened.

76

MAINTENANCE

Carburetor

Your Polaris ATV is calibrated at the factory for optimal performance at
altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of
+40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the
engine air/fuel mixture becomes overly rich and the engine loses
approximately 3% of its power for each 1000-foot (304.8 m) increase in
elevation. Although this power cannot be regained, adjustments to the
carburetor and drive system can be made to allow more efficient opera­tion. Optional jets, available from your Polaris dealer, are required for
operation above 6,000 feet and temperatures below +40 degrees F. (4
degrees C.)

Tip: Continuous operation of the engine without proper jetting when required

can cause poor performance, overheating or PVT or engine damage. See
your Polaris dealer for more information about jetting the ATV for conditions
in your area.

Carburetor/Engine Idle RPM Adjustment

If the engine idle speed is not satisfac­tory, and all other conditions are favor­able, the carburetor can be adjusted.

1. Place the transmission in gear . Lock
the parking brake.

2. Start the engine and allow it to warm

up for approximately five minutes.

3. Turn the screw in (clockwise) to

raise RPM. Turn the screw out
(counterclockwise) to lower RPM.

Idle

Adjuster

77

MAINTENANCE

Drive Chain

Drive Chain Lubrication

Polaris ATV drive chains are equipped with o-ring-sealed, permanently
greased pins and rollers. However, the outer surfaces of the roller must
be lubricated.

Always inspect the drive chain prior to operating the vehicle. Check for
damaged or missing o-rings or damaged rollers. Also check for correct
slack adjustment. Maintain the stone guard to rear sprocket clearance at
1/8” (3 mm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80­90 lube or an approved o-ring chain spray lube. See page 103 for the
part numbers of Polaris products.

NOTICE: Washing the drive chain with a high pressure washer or gasoline can

cause damage to the o-rings, causing premature wear and driv e
chain failure. Do not use a high pressure washer or gasoline to clean
the drive chain.

78

MAINTENANCE

Drive Chain

Rear Drive Chain Slack

Check the amount of chain slack in three different locations by moving
the vehicle slightly forward to gain slack at the top side of the rear
chain. Measure the chain slack at the tightest of the three positions. At
this point the chain should have 3/16"-3/8" (5 mm - 10 mm) deflection.

NOTICE: Adjusting or operating the ATV with improper rear drive chain slack

can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.

Use the following procedure if adjustment is required.

1. Remove the chain guard (if
equipped).

2. Loosen the chain guide.

3. Loosen the two eccentric

locking bolts.

4. Loosen the caliper mounting

bolt located on the left side
of the swing arm.

5. Insert a pin punch through

the sprocket hub and into the eccentric housing.

1

3/16"-3/8" (5 mm - 10 mm)

Locking Bolts

Pin Punch

79

MAINTENANCE

Drive Chain

Rear Drive Chain Slack

6. Roll the ATV forward or backward
to adjust the chain slack to the
proper tension. See the illustration
for proper splice link clip opening
position.

7. Tighten the eccentric locking bolts
to 30 ft. lbs. (41 Nm) for machines
without the hitch and 45 ft. lbs. (61
Nm) for machines with a hitch.

8. Tighten the caliper mount bolt to 15
ft. lbs. (20 Nm)

9. Remove the pin punch.

10. Roll the ATV forward, checking chain tension in several places
around the chain.

Tip: The chain is adjusted correctly when the tightest portion of the chain has

approximately 3/8" (10mm) deflection.

11. Position the chain guide to allow 1/8" (3 mm) clearance and tighten
the retaining bolt to 5 ft. lbs. (7 Nm).

12. Reinstall the chain guard (if equipped).

Clip

Position

80

MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.

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

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height. Include rider
weight on the seat when measuring.

5. Start the engine. Turn the headlight switch to high beam.

6. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the
wall.

7. Loosen the pivot bolt and adjust the beam to the desired position.

8. Tighten the bolt and torque to 60 in. lbs. (7 Nm).

25 ft.

(7.6 m)

2" (5 cm)

X

X

81

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.

Headlamp Replacement

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.

1. Remove the wire harness connector from the back of the headlight.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool
before servicing.

2. Grasp the bulb housing and turn it counterclockwise to remove the
bulb.

3. Apply dielectric grease to the light bulb socket before installing the
new bulb. Install the replacement bulb into the headlight housing
and rotate clockwise firmly.

Tip: The bulb must be positioned so the harness installs into the lamp at the bot-

tom.

4. Reinstall the connector to the back of the headlight.

82

MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover
mounting screws. Remove the
lens cover and gasket and set
aside for reassembly.

2. Remove the lamp.

3. Apply dielectric grease to the

socket and install the new lamp.

4. Test the taillight/brake light for

proper operation.

5. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

1. Remove the instrument panel or front cover, if necessary, to access
the back of the indicator panel.

2. Using a small, straight-blade screwdriver, turn the base of the bulb

1/4 turn counterclockwise.

3. Using a needle-nose pliers or similar tool, pull the lamp out of the

indicator panel housing.

4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.

5. Reinstall the instrument panel or front cover.

Lamp

83

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on p age 1 08 for the recom­mended spark plug type and gap for your veh icle. Torque spark plugs to
specification.

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 84.

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

1. Rotate the spark plug cap.

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

3. Inspect the electrodes for wear
and carbon buildup. Replace
worn or fouled plugs. Verify that
the gap is at specification before
installation.

4. Reverse the procedure for spark
plug installation. Torque to
specification.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

84

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Spark Plug

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

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

Wet Fouled Spark Plug

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, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil, improper use of the chok e, or incorrect throt­tle body/carburetor adjustments.

85

MAINTENANCE

Vehicle Immersion

If your vehicle becomes immersed, major en gine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine.

If it's impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.

1. Move the vehicle out of the

water.

2. Turn the fuel valve off.

3. Check the air box. If water is
present, dry the air box and
replace the filter with a new filter.

4. Remove the spark plug.

5. Loosen the carburetor drain screw
and drain the carburetor.

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

7. Dry the spark plug. Reinstall the plug
or install a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

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

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

12. If water has been ingested into the PVT, follow the procedure on
page 89 for drying out the PVT.

Drain Screw

86

MAINTENANCE

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from th e are a . Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.

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

1. Position the vehicle on a
level surface.

2. Place the transmission in

neutral.

3. Lock the parking brake.

4. Remove the arrestor

clean-out plug from the
bottom of the muffler.

5. Start the engine.

6. Quickly squeeze and release the throttle lever several times to purge

carbon from the system.

7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

8. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 6.

9. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

10. Place the transmission in neutral. Lock the parking brake. Repeat

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.

12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

WARNING

Exhaust

Outlet

Clean-Out Plug

87

MAINTENANCE

PVT System

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 inst all it
in any other product.

• Always make sure th e PVT housing is securely in place during operation.

WARNING

88

MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of pinch applied to the
drive belt. Similarly, if the engine speed decreases, the amount of cen­trifugal force decreases, reducing the amount of belt pinch. This begins
to occur at speeds of less than 5 MPH (8 km/h), due to the system's
dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h), the
engine would be running at only about 1500 RPM, with an engagement
speed of about 1400 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. Belt slip is responsible for creating the
excessive heat that destroys belts, wears clutch components and causes
outer clutch covers to fail.

If the ATV will be operated for extended periods below 5 MPH (8 km/
h), or for towing loads, we recommend that you install a one tooth
smaller counter shaft sprocket to raise the operating RPM far enough
above the engagement RPM to reduce heat caused by incomplete
engagement. Reducing the temperature inside the clutch cover greatly
extends the life of the PVT components (belt, cover, etc.).

Tip: Avoid heavy pulling and extended low-speed operation.

89

MAINTENANCE

PVT System

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. Move the vehicle out of the water.

2. Remove the PVT drain plug. Allow the water to drain completely.

Reinstall the drain plug.

3. Start the engine. Place the transmission in neutral.

4. 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.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission into forward gear.

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

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

90

MAINTENANCE

Battery

Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your ATV may have either a sealed battery, which requires little mainte­nance, or a conventional battery . A sealed battery can be identified by its
flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the termi­nals with dielectric grease or petroleum jelly. Be careful not to allow
cleaning solution or tap water into a conventional battery.

WARNING

WARNING

91

MAINTENANCE

Battery

Battery Removal

1. Place the transmission in gear.

2. Lock the parking brake.

3. Disconnect the battery hold-down strap.

4. Remove the battery cover.

5. On conventional batteries, remove the battery vent tube.

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

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

8. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the
vehicle.

92

MAINTENANCE

Battery

Battery Installation

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 94 before installing the
battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery h old er.

3. With conventional batteries, install the b attery vent tube (seal ed bat­teries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.

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

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

7. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.

93

MAINTENANCE

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.

Tip: Power plug leads may need to be bent down so that the battery cover can

be installed.

Polaris recommends maintaining battery charge by using a Polaris Bat­tery Tender charger or by charging about once a month to make up for
normal self-discharge. Battery Tender can be left connected during the
storage period, and will automatically charge the battery if the voltage
drops below a pre-determined point. See page 103 for the part numbers
of Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will
deteriorate rapidly . Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.

Add only distilled water. Tap water
contains minerals that are harmful to
a battery.

Lower

Mark

Upper

Mark

94

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 91.

2. Charge the battery with a charging output no lar ger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific grav­ity to 1.270 or greater.

3. Reinstall the battery . See page 92. Make sure the positive termi nal is
toward the front of the vehicle.

Battery Charging (Sealed Battery)

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

The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never 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.

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.

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 battery voltage is 12.8 or greater.

3. 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.

95

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of
charging.

State of

Charge

Voltage Action

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

100% 12.8-13.0 volts None, check at 3

mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

verify state of charge

0%-25% 11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

96

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance
but it can also extend the life of various components.

NOTICE: High water pressure may damage components. Polaris recommends

washing the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will

damage plastic surfaces. Do not allow these types of products to
contact the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamoi s to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the
finish.

97

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the follow­ing items:

If an informational or graphic label becomes illegible or comes off, con­tact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge.

Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.

• Wheel bearings • Electrical components/wiring

• Radiator (if equipped) • Switches and controls

• Transmission seals • Cab and body panels

• Brakes • Labels and decals