Polaris 2010 Scrambler 4X4 International Owner's Manual

Pantone 425 C

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER operate:

S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
S on public roads - a collision can occur with another

vehicle.
S with a passenger - passengers affect balance and

steering and increase risk of losing control.

ALWAYS:
S use proper riding techniques to avoid vehicle

overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect

handling and control.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

ALWAYS USE

AN APPROVED

HELMET AND
PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

For your nearest Polaris dealer,
visit www.polarisindustries.com

Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.

Part No. 9922463 Rev 01
Printed in U.S.A.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

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

®

Always follow the instructions and recommendations in this manual.
The 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. Please see your dealer for all of your service needs
during (and after) the warranty period.

For more information about Polaris, visit us online at
www.polarisindustries.com.

2

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

Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2010 Scrambler 4X4 International Owner’s Manual
P/N 9922463

3

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Emission Control Systems . . . . . . . . . . . . . . . 46

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 99

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 100

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 104

Declaration of Conformity . . . . . . . . . . . . . . . 106

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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 follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.

Read and understand your owner's manual and all warnings before operating
this Polaris vehicle.

Safety Training

When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa­tion on a regular basis.

If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.

Age Restrictions

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

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited.

Equipment Modifications

The warranty on your Polaris vehicle may be terminated if any equip­ment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.

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

Failure to operate the vehicle 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.

Equipment Modifications

We strongly recommend that consumers do not install on a Polaris vehi­cle 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 vehicle 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.

WARNING

8

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding a Polaris vehicle. 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
Transportation (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.

10

SAFETY

Operator Safety

Read and understand all warnings, cautions
and operating procedures in this manual and
on the safety labels before operating the
vehicle.

Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified
instructor. Contact an authorized Polaris
dealer or visit the Polaris web site at
www.polarisindustries.com.

Never permit others to operate the vehicle unless they have read and under­stand this manual and all product labels, and have completed a certified safety
training course.

Never allow anyone under 16 years of age to
operate this vehicle.

Never carry a passenger.

11

SAFETY

Operator Safety

Always wear an approved helmet that fits
properly. Wear eye protection (goggles or face
shield), gloves, boots, long sleeves and long
pants.

Never consume alcohol or drugs before or while
operating this vehicle.

Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.

Never attempt jumps or other stunts.

12

SAFETY

Operator Safety

Always inspect your Polaris vehicle before each
use to verify that it's in safe operating condition.
Follow the inspection and maintenance procedures
outlined in this manual. See page 30.

Keep both hands on the handlebars. Keep
your feet on the footrests.

Always travel slowly when operating on
unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery
or loose terrain.

Always follow the procedures outlined in this
manual for turning. See page 34.

Never turn sharply at excessive speeds,
which can lead to vehicle overturn.

13

SAFETY

Operator Safety

If the vehicle has been involved in an accident, always have an authorized
Polaris dealer inspect the entire vehicle for possible damage, including (but not
limited to) brake, throttle and steering systems.

Never operate on hills too steep for the vehicle or
for your abilities. Practice on smaller hills before
attempting larger hills. Avoid climbing hills steeper
than 25°.

Always follow the procedures outlined in this
manual for climbing hills. See page 36.

Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills. See page 38.

Always follow the procedures outlined in this
manual for crossing the side of a hill. See page

37.
Never attempt to turn the vehicle around on any

hill until you've mastered (on level ground) the
turning technique outlined in this manual.

Always follow the procedures outlined in this
manual for braking if you stall or roll backwards
while climbing a hill. Never back down a hill. See
page 39.

+25°

14

SAFETY

Operator Safety

Always follow the procedures outlined in this manual for operating over
obstacles. See page 41.

Always follow the procedures outlined in this manual for operating on slippery or
loose surfaces. Use extra caution. Always avoid skidding or sliding. See page

35.

Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page 40.

Always follow the procedures outlined in this manual for driving in reverse. See
page 42.

Always use the size and type of tires specified for
your vehicle. Maintain the proper tire pressure.

Never modify this Polaris vehicle
through improper installation or use of
accessories.

Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.

15

SAFETY

Operator Safety

Never exceed the stated load capacity for your vehicle. Cargo must be properly
distributed and securely attached. Reduce speed and follow the instructions in
this manual for carrying cargo or towing. Allow a greater distance for braking.

Never operate this vehicle on a frozen body of water.

Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 27.

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 refu­eling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.

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

Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.

For more information about safety, contact an authorized

Polaris dealer or visit the Polaris web site at

www.polarisindustries.com.

16

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

17

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

+

General

Warning

+

Discretionary

Warning

18

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 weight capacity: 275 lbs. (125 kg)

7175443

+

“No Passenger”

Warning

+

Clutch Cover

Warning

+

Age 16 Warning

+

Tire Pressure/Load

Warning

19

SAFETY

Safety Labels and Locations

Age 16 Warning

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

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

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

4X4 Caution

CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This

may cause severe drive shaft and clutch damage.

7175485

20

FEATURES AND CONTROLS

Switches

Engine Stop Switch

The engine will not start
or run when the switch is
in the OFF position.

OFF

RUN

Push the stop switch
down to stop the engine
quickly. Pull the stop
switch up to the RUN
position before attempt­ing to start the engine.

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

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.

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.

AWD 2X4

Override

Switch

Engine

Stop

Switch

Headlight

Switch

Horn

Switch

Hazard

Switch

21

FEATURES AND CONTROLS

Switches

Headlight Switch

The lights do not operate unless the main key switch is on and the
engine stop switch is in the RUN position.

High Beam

Low Beam

Turn Signal Switch

Push the toggle switch either left or right to activate the corre­sponding turn signal light. The indicator on the pod will also

flash. Return the toggle to the center position and push it inward
to end the signal.

Hazard Switch

Push the hazard warning switch to cause all turn signal lights to
flash simultaneously. Use this feature to alert others of an emer-

gency or other situation requiring caution.

Horn Switch

Press the horn switch to sound the horn.

Main Key Switch

Use the main key switch to start the engine. See page 31 for starting pro­cedures.

All Wheel Drive Switch

See page 28 for all wheel drive information.

AWD 2X4

Main Key Switch

All Wheel Drive

Switch

22

FEATURES AND CONTROLS

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the vehicle.

Indicator Lights

With the engine 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)

Turn Signal/Hazard Indicators

High Beam Indicator

23

FEATURES AND CONTROLS

Throttle Lever

Press the throttle lever to
increase engine speed and
vehicle movement. Release the
lever to reduce engine speed
and vehicle movement.

Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.

Do not start or operate a vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.

Electronic Throttle Control (ETC)

ETC causes the engine to
stop if the throttle cable
sticks in an open position
when the operator releases
the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify the ETC system or replace it with other
throttle mechanisms.

Electronic Throttle Control

24

FEATURES AND CONTROLS

Brakes

Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on
this vehicle. Always use caution whenever applying the brakes.

Foot Brake

The all-wheel foot brake is located
on the right footrest. The foot brake
operates both front and rear brakes.
Press the brake pedal down with
your foot to apply the all-wheel
brakes.

If the rear wheels begin to skid or
slide while using the foot brake,
reduce brake pressure.

Hand Brake Lever

The hand brake operates both
front and rear brakes. Squeeze
the brake lever toward the han­dlebar to apply the all-wheel
brakes.

If the rear wheels begin to skid
or slide while using the hand
brake, reduce lever pressure.

Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.

Foot Brake

25

FEATURES AND CONTROLS

Brakes

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

forward 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.

Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.

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

Gear

Selector

26

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold
engine. Refer to the engine start­ing procedure on page 31 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

fuel with ethanol content greater
than 10 percent, such as 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.

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.

AWD

Fuel Tank

Cap

Fuel

Valve

Fuel

Guage

OFFON

Choke

27

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent
unauthorized use or theft of
the vehicle.

Tip: Place the steering lock

keys in a safe place. The
lock must be replaced if the keys are lost.

1. Turn the handlebars to the full left posi-

tion.

2. Insert the steering lock key and turn it

clockwise. Remove the key.

3. Reverse the procedure to unlock the

steering.

The handlebars are locked in the full left position when the steering is locked.
Always unlock the steering before starting the engine.

AWD 2X4

28

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The AWD switch may be turned on or off while the vehicle is moving.
AWD will not engage until engine speed is below 3100 RPM. AWD
remains engaged until the switch is turned off. There is no limit to the
length of time the vehicle may remain in AWD.

If the switch is turned off while the demand drive unit is engaged, it will
not disengage until the rear wheels regain traction. Engage AWD before
getting into situations where maximum traction is needed. If the rear
wheels are spinning, release the throttle before switching to AWD.

Tip: The override switch allows activation of AWD in reverse if the AWD switch

is on.

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

AWD

When the AWD switch is on,
the vehicle is in four-wheel
drive and the differential is
locked, providing maximum
traction. The demand drive
unit automatically engages
when the rear wheels lose trac­tion. When the rear wheels
regain traction, the demand drive unit automatically disengages.

2X4

When the 2X4 switch is on,
the vehicle is in two-wheel
drive at all times and the dif­ferential is locked.

29

OPERATION

Break-In Period

The break-in period for your new Polaris vehicle 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 will increase the life and performance of
your vehicle more than 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.

Do not operate at full throttle or high speeds for extended periods during
the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 26.

2. Check the oil level. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly. 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 30.

6. Pull only light loads.

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

PVT Break-in (Clutches/Belt)

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.

30

OPERATION

Pre-Ride Checklist

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

Item Remarks Page

Hand brake Ensure proper operation 24

Brake fluid Ensure proper level 59

Foot brake Ensure proper operation 24

Front suspension Inspect, lubricate if necessary 51

Rear suspension Inspect, lubricate if necessary 51

Steering/steering lock Unlock the steering; ensure free

operation

27

Tires Inspect condition and pressure 65

Wheels/fasteners Inspect, ensure fastener tightness 65

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 26

52

Coolant level Ensure proper level 74

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 23

64

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 20

Mirrors Adjust for best side/rear vision 22

Drive chain Check condition/slack, lubricate as

needed

71

Air filter, pre-filter Inspect, clean 68

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

21
77

Brake light/taillight Check operation, apply Polaris dielec-

tric grease when lamp is replaced

78

Riding gear Wear approved helmet, goggles, and

protective clothing

8

31

OPERATION

Starting the Engine

Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.

1. Position the vehicle on a level surface.

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 use the 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. Pull the engine stop switch up to RUN.

Choke

Knob

Adjusting

Nut

32

OPERATION

Starting the Engine

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

9. If the engine does not start, release the starter and wait five seconds.

10. Repeat steps 8 and 9 until the engine starts.

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

11. If a warm engine has cooled to a point where it does not readily

start, intermittent 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.

12. 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.

33

OPERATION

Driving Procedures

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

2. Sit upright. Keep your feet on the footrests. Keep 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 squeeze the throttle lever toward the handlebar to begin

driving.

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

brakes on level surfaces.

34

OPERATION

Turning the Vehicle

1. Before turning, activate

a turn signal to alert oth­ers of your intentions.
Activate the left signal
before a left turn. Acti­vate the right signal
before a right turn.

2. 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. Use
the same leaning tech­nique for turning in
reverse.

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

speeds.

35

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. Be alert.

5. Watch the trail.

6. Avoid quick, sharp turns.

Tip: To correct a rear wheel skid, turn the handlebars in the same direction as

the skid and shift body weight forward.

Sideways

skid

Turn in

direction of

skid

36

OPERATION

Driving Uphill

Whenever traveling
uphill, follow these pre-

cautions:

1. Avoid steep hills (25°

maximum).

2. Check the terrain

carefully.

3. Avoid hills with

excessively slippery
or loose surfaces.

4. Shift your weight

uphill.

5. Drive straight uphill.

6. Keep your feet on the

footrests.

7. Drive at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never
apply the brakes aggressively while rolling backwards.

Apply the brakes gradually. When fully stopped, lock the parking brake.
See page 25.

Dismount on the uphill side, or to either side if the vehicle is pointed
straight uphill. Turn the vehicle around using the K-Turn. See page 39.

25° Maximum

37

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Avoid crossing the sides of steep hills.

4. Shift your weight uphill.

5. Keep your feet on the footrests.

6. If the vehicle begins to tip, quickly turn the front wheels downhill

(if possible) or dismount on the uphill side immediately!

38

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Check the terrain carefully.

2. Avoid hills with excessively slippery or loose surfaces.

3. Never drive downhill at high speed.

4. Slow down.

5. Avoid driving downhill at an angle, which can cause the vehicle to

pitch sharply to one side. Drive straight downhill.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

25° Maximum

39

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 the vehicle. Keep your weight uphill.

2. Lock the parking brake. Leave the transmission in forward gear.

Turn the engine off.

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. Squeeze

the brake lever to release the parking brake.

5. Slowly release the brake lever and 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 from the uphill side. Keep your

weight uphill.

7. Apply the foot brake. Squeeze and release the brake lever to release

the parking brake.

8. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level
ground.

8 ft. (2.4 m)

40

OPERATION

Driving Through Water

Your Polaris vehicle 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 fast­flowing 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 47. 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 81,
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 sudden movements.

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

Maximum Depth

41

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.

42

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.

43

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.

25° maximum

44

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.

When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.

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

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

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

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

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

NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE.
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.

45

OPERATION

Hauling Cargo

Load Distribution

Accessory racks and hitches are available from your Polaris dealer.
Read and understand the load distribution warnings listed on the vehicle
warning labels. Never exceed the specified weights.

Never carry cargo on the front of the vehicle.
Cargo should be evenly distributed and mounted as low as possible on

the rear rack. When operating over rough or hilly terrain, reduce speed
and cargo or towed load to maintain stable driving conditions.

Towing Loads

Towing is approved OFF-ROAD ONLY. Do not exceed the maximum
capacities when towing. Do not tow any trailer on a grade steeper than
15°.

Always attach a towed load to the hitch point. Remove the hitch 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, cargo and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

46

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was designed for on-road
and off-road operation. It is required that this spark arrestor remain
installed and functional when the vehicle is operated.

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.

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.

47

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 chart.

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 111.

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.

48

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.

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 30.

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

X

Q

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

49

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)

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

X Demand drive fluid 25 H Monthly 250 (400) Inspect level; change yearly
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

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

Cooling system
(if applicable)

50 H 6 M 1000 (1600) Inspect coolant strength

seasonally; pressure test
system yearly

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
X Oil tank vent hose

(if equipped)

100 H 12 M 1000 (1600) Inspect routing, condition

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

50

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

X Radiator

(if applicable)

100 H 12 M 1000 (1600) Inspect; clean external

surfaces

X Cooling hoses

(if applicable)

100 H 12 M 1000 (1600) Inspect for leaks

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

51

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 47. Items not listed in the
chart should be lubricated at the General Lubrication interval.

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 52.

Brake Fluid DOT 4 Only See page 59.

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

80/90

Lubricate.

Transmission Oil AGL Synthetic Gearcase

Lube

See page 56.

Demand Drive Fluid
(Front Gearcase)

Demand Drive LT
Premium Fluid

See page 58.

Front Prop Shaft
Yoke

Premium U-Joint Lube Grease fittings (3 pumps maximum)

every 500 miles (800 km), before long
periods of storage, or after pressure
washing or submerging.

Front Prop Shaft Yoke

52

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil.
Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to
be changed more frequently if Polaris oil is not used. Always use 2W-50
oil. Follow the manufacturer's recommendations for ambient tempera­ture operation. See page 99 for the part numbers of Polaris products.

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.

Make sure the cap is fully seated
to keep the angle and depth of the
stick consistent.

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

2 qts. (1.9 l) 14-17 ft. lbs. (19-23 Nm)

Safe

Add Oil

{

Safe Range

53

MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 47. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface. Clean the area around the
drain plug at the bottom of the oil tank and the bottom of the engine.

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

engine.

3. Place a drain pan under the oil tank. Remove the drain plug. Allow

the oil to drain completely.

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

4. Reinstall the drain plug with

a new sealing washer.
Torque to specification. See
page 52.

Tip: The sealing surfaces on the

drain plug and crankcase
should be clean and free of
burrs, nicks or scratches.

5. Disconnect the lower oil

delivery hose and remove
the screen fitting from the
oil tank. Clean the fitting.

NOTICE: The fitting threads must

be sealed with LOCTITE
PST 505 or PTFE seal
tape.

6. Reinstall the screen fitting

and rotate the fitting clock­wise a minimum of 2 1/2
turns into the tank threads. Continue to rotate the fitting until the
nipple of the fitting aligns with the mark on the tank.

NOTICE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft.

lbs. (34 Nm).

7. Reattach the oil line.

Screen
Fitting

Sealing
Washer

Drain
Plug

Mark

54

MAINTENANCE

Oil and Filter Change

8. Place towels under the oil filter.
Using an oil filter wrench, turn
the filter counterclockwise to
remove it.

9. Lubricate the gasket on the new
filter with a film of new engine
oil. Check to make sure the
gasket is in good condition.
Make sure the gasket from the
old filter is not still on the
engine.

10. Install the new oil filter. After
the filter contacts the engine
surface, turn it 1/2 to 3/4 turn
by hand.

11. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank­case.

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

free of burrs, nicks or scratches.

12. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

13. Remove the dipstick. Add the recommended oil. See page 52. Rein­stall the dipstick.

Tip: If the sump is not drained, add about 1 3/4 quarts initially.

14. Place the transmission in neutral. Lock the parking brake.

15. Prime the oil pump using the procedure on page 55. Then stop the
engine and inspect for leaks.

16. Remove the dipstick and check the oil level. Add oil as needed.
Maintain the oil level in the safe range. Do not overfill.

17. Discard used oil and filter properly.

Filter

55

MAINTENANCE

Oil and Filter Change

Oil Pump Priming

This priming procedure must
be performed whenever the oil
hose connection between the
oil tank and pump inlet has
been disconnected.

1. Clamp or pinch off the vent
line approximately two
inches (5 cm) from the oil
tank, between the end of
the oil tank vent fitting and
the vent line's pressure
relief slit.

2. Run the engine for 10-20

seconds.

3. Remove the vent line

clamp. If the line is bled
properly, you should hear a
rush of air, indicating that
the line is properly primed
and ready for operation. If

you do not hear air, the
line has not bled, and
you'll need to repeat the
priming procedure.

Relief

Slit

2” (5 cm)

Vent

Line

Oil

Ta n k

56

MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 47. Maintain the
oil level at the bottom of the fill hole threads. See page 99 for the part
numbers of Polaris products.

The fill plug is located on the left side of the vehicle, under the rear
fender, behind the wheel. The drain plug is located behind the wheel
well.

Transmission Oil Recommendations

Oil Check

1. Position the vehicle on a level sur­face.

2. Remove the propshaft shield from

the right side of the vehicle to
access the fill plug. Remove the
fill plug.

3. Check the oil level. Add oil as

needed. Do not overfill.

4. Reinstall the fill plug. Torque to

specification.

Gearcase Lubricant Capacity Fill Plug

To r q u e

Drain Plug

To r q u e

Transmission Premium AGL Synthetic

Gearcase Lubricant

32 oz.

(946 ml)

14 ft. lbs.

(19 Nm)

14 ft. lbs.

(19 Nm)

Fill Plug

57

MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the propshaft shield from the right side of the vehicle to
access the fill plug. Remove the fill plug.

3. Remove the transmission drain plug located on the bottom left-hand
side and drain the oil into an appropriate container. Discard used oil
properly.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the proper amount of the recommended lubricant.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

8. Reinstall the propshaft shield.

58

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out­lined in the Periodic Maintenance Chart beginning on page 47. Maintain
the fluid level at the bottom of the fill hole threads. See page 99 for the
part numbers of Polaris products.

Fluid Recommendations

Fluid Check

The fill plug is located on the right side of the demand drive unit.

1. Position the vehicle on a
level surface.

2. Remove the fill plug.

Check the fluid level.

3. Add the recommended

demand drive fluid as
needed to bring the level
to the bottom of the fill
hole threads.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

The drain plug is located on the bottom right side of the unit.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Place a drain pan under the demand drive unit. Remove the drain

plug. Allow the fluid to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended fluid to capacity.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

8. Dispose of used fluid properly.

Gearcase Lubricant Capacity Fill Plug

To r q u e

Drain Plug

To r q u e

Front

Gearcase

Demand Drive LT

Premium Fluid

9 oz.

(265 ml)

8-10 ft. lbs.
(11-14 Nm)

11 ft. lbs.

(15 Nm)

Drain Plug

Fill

Plug

Fill Level

59

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for ser­vice.

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

If the fluid level is low add DOT 4 brake fluid only. See page 99 for the
part numbers of Polaris products.

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

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.

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

60

MAINTENANCE

Brake Fluid

Hand Brake

The master cylinder is
located on the left
handlebar. Maintain the
fluid level 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.

Foot Brake

1. Position the vehicle on a level surface.

2. The brake fluid reservoir is located either under the seat or near the

foot brake. View the fluid level in the master cylinder.

3. Maintain the fluid level between the minimum and maximum

marks. Do not overfill.

Master

Cylinder

Indicator

Window

61

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes. Both brake systems
are self-adjusting.

Brake Inspections

Perform the following checks to keep the brake systems 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 59.

2. Check the brake systems regularly

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.

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. Remove the push-pins at the front and rear of the side panel.

3. Grasp the rear of the side panel near the rear cab. Pull the panel

slightly outward, downward and rearward to disengage the upper
front section.

4. To reinstall the side panel, align the upper and lower front section

with the mating front cab tabs. Push the panel upward and forward
until the panel is fully seated at the front. Lock the rear of the panel
into the rear front cab tabs. Reinstall the push-pins at the front and
rear of the side panel.

1 mm

62

MAINTENANCE

Toe Alignment

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be
performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 3-6 mm toe out.

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

63

MAINTENANCE

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts
and bolts. If loose nuts and bolts are found, see your Polaris dealer for
service before operating the vehicle.

Rear Suspension

The rear suspension spring pre­load and shock compression
damping may be adjusted to suit
different riding conditions and
operator weight.

Spring Preload

1. Raise and safely support the
rear of the vehicle off the
ground to allow the suspen­sion to fully extend.

2. Loosen the jam nut and
back it away from the
adjusting ring.

3. As viewed from the top of
the shock, turn the adjusting
ring clockwise (1) to
increase preload. Turn the
ring counter-clockwise (2)
to decrease preload.

4. Tighten the jam nut firmly

against the adjuster ring.

2

1

Locking

Ring

Adjusting

Ring

64

MAINTENANCE

Throttle Cable Freeplay

Adjust throttle cable freeplay at the
handlebar.

1. Slide the boots off the inline cable
adjuster sleeve. Loosen the
adjuster locknut.

2. Turn the adjuster until 1.5-3 mm of

freeplay is achieved at the thumb
lever. Move the throttle lever back
and forth several times while
adjusting.

3. Tighten the lock nut and slide the

boots over the cable adjuster until
they touch at the midpoint of the
adjuster.

Tip: Engine RPM should not increase when steering is turned full left or right.

Readjust cable freeplay if this occurs.

1.6-3 mm

Lock Nut

Sleeve

Boot

Boot

65

MAINTENANCE

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident.

• Maintain proper tire pressure as described on the label on your vehicle and in
the specifications section of the owner's manual.

• Use only original equipment size and type when replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Refer to the specifications section beginning on page 104 for recom­mended tire type, size and pressure.

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.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 3 mm or less.

WARNING

3 mm

66

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.

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 67).

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.

67

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)

50 ft. lbs. (68 Nm)27 ft. lbs. (37 Nm)

68

MAINTENANCE

Air Filter

1. Remove the seat.

2. Release the air box cover

clips, and remove the air
box cover.

3. Loosen the clamp and

remove the filter.

4. Remove the fabric type pre-

filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.

5. Reinstall the pre-filter over

the main filter. Install a new
main filter if needed.

6. Reinstall the filter into the

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

7. Reinstall the air box cover and the seat.

Breather Filter

The breather filter is on the hose that runs between the engine and air
box.

1. Remove the clamps and pull the breather filter out of the hoses. It's
not necessary to remove the lower hose from the engine.

2. Inspect the filter for debris. Blow gently through the filter in the

direction of the arrow to check for clogging. Replace if needed.

3. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

4. Reinstall the filter and secure the clamps. The filter is effective with

the arrow pointing in either direction.

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

Main Filter

Pre-Filter

Breather

Filter

69

MAINTENANCE

Handlebars

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control. 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 the front two bolts to 14-17 Nm, then torque the rear two

bolts. A gap of up to 3 mm will remain at the rear bolts.

Handlebar Bolts

70

MAINTENANCE

Carburetor

Your Polaris vehicle is calibrated at the factory for optimal performance
at altitudes ranging from zero to 1800 meters and at temperatures of 4
degrees C. or higher. Above 1800 meters the engine air/fuel mixture
becomes too rich and the engine loses approximately 3% of its power
for each 300 meter 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 and clutch components,
available from your Polaris dealer, are required for operation above
1800 meters and at temperatures below 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 vehicle 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

71

MAINTENANCE

Drive Chain

Drive Chain Lubrication

The 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 99 for the part
numbers of Polaris products.

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

72

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.

Adjusting or operating the vehicle 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.

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

73

MAINTENANCE

Drive Chain

Rear Drive Chain Slack

6. Roll the vehicle 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 vehicle 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.

Clip

Position

74

MAINTENANCE

Cooling System

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

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

Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool­ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. Polaris Premium 60/40 is already premixed
and ready to use. Do not dilute with water. See page 99 for the part num­bers of Polaris products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located on
the left side of the vehicle.

1. Maintain the coolant level
between the minimum and
maximum marks on the bottle
(when the fluid is cool).

2. Add coolant as needed.

Recovery Bottle

75

MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,
Polaris recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. Add coolant as needed.

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

1. Remove the front panel to access
the radiator pressure cap.

2. Remove the pressure cap.

3. If coolant is low, use a funnel and

slowly add coolant through the
radiator filler neck.

4. Reinstall the pressure cap. Use of

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

5. Secure the front panel.

6. Fill the coolant recovery bottle to

the upper mark on the bottle.

7. Check the coolant level in the bottle frequently, adding coolant as

needed until the level stabilizes.

Radiator Cap

76

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. Switch the headlight 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. Tighten or loosen the lower headlight screws to adjust the beam

upward or downward or to the left or right.

25 ft.

(7.6 m)

2" (5 cm)

X

X

77

MAINTENANCE

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.

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

Headlamp Replacement

When servicing a halogen lamp, do
not 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. Hold the plastic
part of the lamp.

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

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.

78

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, 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 if removed.

Screw

Lamp

Cover

79

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 104 for the recom­mended spark plug type and gap for your vehicle.

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

damage. Always use Polaris-recommended spark plugs.

Spark Plug Inspection

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 80.

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 12-15 Nm

Previously Installed Spark Plug 23-27 Nm

80

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 choke, or incorrect throt­tle body/carburetor adjustments.

81

MAINTENANCE

Vehicle Immersion

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

If it's impossible to take your vehicle 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. Have the vehicle serviced by your
dealer promptly, whether you succeed in starting it or not.

12. If water has been ingested into the transmission, follow the proce­dure on page 85 for drying.

Drain Screw

82

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 the area. 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. 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

83

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 install it
in any other product.

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

WARNING

84

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 vehicle 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.

85

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.

86

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 vehicle 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

87

MAINTENANCE

Battery

Battery Removal

1. Place the transmission in gear.

2. Lock the parking brake.

3. Remove the seat.

4. Disconnect the battery hold-down strap.

5. Remove the battery cover (if equipped).

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

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

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

9. Lift the battery out of the vehicle. Be careful not to tip a conven-

tional 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.

88

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 90 before installing the
battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed 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.

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 (if equipped).

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.

10. Reinstall the seat.

89

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 99 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

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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 87.

2. Charge the battery with a charging output no larger 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 88. Make sure the positive terminal 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.

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.

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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

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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 chamois 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.

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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 • Switches and controls

• Transmission seals • Cab and body panels

• Brakes • Labels and decals

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MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre­serve wheel life and ensure a “like new” appearance for many years.
Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean chrome
wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out­lined above.

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MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur. Never
start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See
page 92.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
Follow the instructions on the container for the recommended
amount. Carbon Clean removes water from fuel systems, stabilizes
fuel and removes carbon deposits from pistons, rings, valves and
exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.

4. Turn the fuel valve off.

5. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 53.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Clean or replace the breather filter.

4. Drain the sediment tube.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic
Maintenance Chart beginning on page 47.

• Demand drive unit (front gearcase)

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. See page 95.

2. Support the front end of the machine so the engine is level or tilted

slightly rearward.

3. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of engine

oil into the hole.

Tip: Use a section of small hose and a small plastic squeeze bottle filled with the

pre-measured amount of oil.

4. Reinstall the spark plug. Torque to specification.

5. Apply dielectric grease to the inside of the spark plug cap. Reinstall

the cap.

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

be forced in and around the piston rings and ring lands, coating the
cylinder with a protective film of fresh oil.

7. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline.

8. To eliminate any fuel remaining in the carburetor, run the engine

until it stops.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 47.

Battery Storage

See pages 89-90 for storage and charging procedures.

Storage Area/Covers

Set the tire pressure and safely support the vehicle with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine Polaris cover. Do not use plastic or coated mate­rials. They do not allow enough ventilation to prevent condensation, and
may promote corrosion and oxidation.