Polaris Phoenix 200, 2014 Phoenix 200 Owner's Manual

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Read this manual carefully. It contains important safety information.
Adult supervision is required for children under 16 years of age.
Operation is prohibited for children under 14 years of age.
PMS 419
Owner's Manual
for Maintenance and Safety
Phoenix 200
Page 2
A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800­342-3764 for assistance.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
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Dear Parents:
We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We've provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV.
A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will operate the ATV takes a training course before operating the ATV. Make sure all operators under­stand and follow all of the instructions and warnings contained in this owner’s manual. Help them also learn to show respect for our
environment and for the rights of others while operting the ATV.
Never allow a child under the age of 16 to operate an ATV without adult supervision. Children differ in skills, physical abilities and
judgement. Some children may not be able to operate an ATV safely. Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely.
For your child’s safety, be sure your child can reach and operate all ATV controls, including handlebars, brake levers, throttle lever and engine stop switch.
The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's ATV are thoroughly inspected at specific intervals. Follow all of the instructions and recommendations in this manual.
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Dear Children:
Before you ride your new Polaris ATV, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner's manual. You must also take an ATV training course before you begin riding.
Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times. Never drive your ATV alone. Always make sure an adult is watching you when you ride.
Drive safely and enjoy riding your new Polaris ATV!
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1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
RANGER® utility vehicles
RZR® sport vehicles
• VICTORY® motorcycles
• GEM® vehicles We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
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2
POLARIS® is a registered trademark of POLARIS Industries Inc. Copyright 2013 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 inacc uracies. Any reprin ting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.
Printed in Taiwan 2014 Phoenix 200 Owner’s Manual P/N 9924651
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 93
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 96
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . 98
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 106
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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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 ha zard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could 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.
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5
INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV.
• Never operate an ATV without proper instruction. Take a certified A TV safety training course (www.atvsafety.org).
• For your child’s safety, be sure your child can reach and operate all ATV controls, including handlebars, brake levers, throttle lever and engine stop switch.
• Adul t supervision is required for children under age 16.
• NEVER allow anyone under 14 years of age to operate this vehicle.
• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course (www.atvsafety.org).
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration lev­els of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was con-
trolled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING
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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: ___________________________________________________
VIN
Engine Serial Number
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SAFETY
Safety Training
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse
sm
that is available to you and your eligible family members. This training is included in the purchase price of your ATV. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.
If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCourse
sm
for a fee. Call ATV Enrollment Express
at (800) 887-2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the United States, please
contact your dealer or local law enforcement agencies for information about safety training.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
W e strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehi­cle are thoroughly inspected at specific intervals
FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800­638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.
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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. W ear protective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab­lished safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportati on (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
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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-ankle boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Rid­ing pants with kneepads and a jersey with shoulder pads provide the best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mow­ers, blades, tires, sprayers, or large racks, may change the handling char ­acteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.
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SAFETY
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.
Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.
Never permit a guest to operate the A TV unless the guest has read this manual and all product labels and has completed a certified safety training course.
Age Restrictions
This vehicle is for recreational use by adults or young operators under adult supervision.
Adult supervision is required for children under age 16.
NEVER permit children under age 14 to operate this ATV.
WARNING
UNDER
14
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SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel wi th the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe operating condition before operating increase s the risk of an accident.
Always inspect the ATV before each use to make sure it's in safe operating condition.
Always follow all inspection and maintenance procedures and schedules described in the owner's manual.
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SAFETY
Safety Warnings
Protective Apparel
Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident.
Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket and long pants.
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.
Never consume alcohol or drugs before or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or rollover.
Never carry a passenger on this ATV.
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SAFETY
Safety Warnings
Operating on Pavement
Operating an A TV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or rollover.
Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads or highways could result in a collision with another vehicle.
Never operate the A TV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.
Operating at Excessive Speeds
Operating the ATV at excessive speeds increases the operator's risk of losing control.
Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.
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SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.
Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or rollover.
Always follow proper procedures for turning as described in the owner's manual.
Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover.
Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of control or rollover. Always follow proper procedures for climbing hills as described in the owner's manual. See page 41.
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SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss of control or rollover.
• Always follow proper procedures for travel-
ing down hills as describe d in t h e ow n er's manual. NOTE: A special technique is required when braking while traveling down­hill. See page 43.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with the transmission in neutral.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 42.
Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 44.
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SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover.
• Always maintain a steady speed when climbing a hill.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the front brakes (right lever).
• When fully stopped, apply the rear brake as well, and then lock the parking brake.
• Lock the parking brake when fully stopped.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure descri bed in the owner's manual. See page 44.
If the ATV begins rolling downhill:
• Keep body weight uphill.
• Appl y the front brakes gradually.
• Never apply the rear brake while rolling backwards.
• Never apply engine power.
• When fu lly stopped, apply the rear brake as well, and then lock the parking brake.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure descri bed in the owner's manual. See page 44.
Operating on Steep Hills
Operating on excessively steep hills could cause a rollover.
Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.
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SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.
Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on
safety labels.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 47.
Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.
Operating on Slippery Terrain
Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover.
Do not operate on excessively rough, slippery or loose terrain. Always use extra caution on rough, slippery or loose terrain.
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SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 46.
Skidding or Sliding
Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.
Operating Through Deep Water
Operating the ATV through deep or fast­flowing water could cause the tires to float, causing loss of control or rollover.
Avoid operating the A TV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page
45):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water.
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SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the A TV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.
• Never exceed the stated load capacity for this ATV.
• Cargo should be properly distributed and securely attached.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater dis-
tance for braking.
• Always follow the instructions in the owner's manual for carrying cargo or
pulling a trailer.
Poor Visibility
Operating the A TV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of rollover and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.
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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
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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
+
Discretionary
Warning
General
Warning
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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: 4.0 psi (27.6 kPa)
• Maximum weight capacity: 215 lbs. (98 kg)
7175445
“No Passenger”
Warning
Clutch Cover
Warning
Age
Warning
Tire Pressure/Load
Warning
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SAFETY
Safety Labels and Locations
Age Warning
WARNING Operation of this ATV by children under the age of 14 increases the risk of
severe injury or death. Adult supervision is required for children under age 16. NEVER permit children under age 14 to operate this ATV.
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. T o 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
7173313
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FEATURES AND CONTROLS
Switches
Light Switch
Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position to operate the headlights.
Engine Stop Switch
Before starting the engine, press the upper end of the switch down to the ON position. To stop the engine, press the lower end of the switch down to the OFF position. The engine will not start or run when the switch is off.
Main Key Switch
Turn the main key switch clockwise to the ON position before starting the engine. Turn the main switch off to stop the engine and end all elec­trical power to the vehicle.
Start Button
To start the engine, make sure the stop switch is in the ON position. Turn the main key switch on. Press the start button.
Override
Switch
ON
OFF
Start
Button
Light
Switch
Engine
Stop Switch
Main Key
Switch
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FEATURES AND CONTROLS
Switches
Override Switch (Reverse Speed Limiter)
This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch.
WARNING! Pressing the override button whi le 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 button.
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is installed and properly routed to the throttle control.
Engine speed and vehicle movement are controlled by pressing the throt­tle lever. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.
This ATV is equipped with POLARIS Electronic Throttle Con­trol (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
WARNING
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26
FEATURES AND CONTROLS
Brakes
Operating the A TV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
Aggressively applying the rear brakes when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.
Use caution when applying the rear brakes. Do not aggressively apply the rear brakes when going forward. The rear wheels may skid and slide sideways, causing loss of control, which may result in serious injury or death.
Front Brakes (Right Lever)
Squeeze the right brake lever toward the handlebar to apply the hydraulic front wheel brakes. This lever does not
apply the rear brakes.
Always test front brake lever travel and master cylinder fluid level before rid­ing. When squeezed, the lever should feel firm. Any sponginess would indi­cate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
WARNING
WARNING
Front Brakes
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FEATURES AND CONTROLS
Brakes
Rear Brakes (Left Lever)
Squeeze the left brake lever toward the handlebar to apply the mechanical rear wheel brakes. This lever does not
apply the front brakes.
Rear Brakes (Foot Brake)
The foot brake operates the rear brakes. The foot brake is located on the inside of the right footrest. Operate this brake with your right foot. The foot brake is a mechanical rear wheel brake.
If the rear wheels slide while using the foot brake, reduce brake pedal pres­sure to brake the rear wheels without skidding.
Rear Brakes
Foot Brake
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FEATURES AND CONTROLS
Brakes
Parking Brake
1. Place the transmission in
gear.
2. Squeeze and release the left
brake lever two or three times, then squeeze and hold.
3. Push the parking brake lock
down to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
Page 33
29
FEATURES AND CONTROLS
Brakes
Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid level in the master cylinder before each ride. Always maintain brake fluid at the recommended level.
The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6.3 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. V iew 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. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
Tip: Under normal operation, the diaphragm extends into the reservoir as fluid
level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper dia­phragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.
WARNING
Master
Cylinder
Indicator
Window
Page 34
30
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 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.
Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See page 98 for the part numbers of POLARIS products.
Use either leaded or unleaded gaso­line with a minimum pump octane number of 87=(R+ M/2) octane. Non-ethanol fuel is recommended. 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.
ON: For normal operation. OFF: For vehicle storage
and when transporting. RES: Turn the valve to the
reserve setting if the main fuel supply is exhausted. Refuel as soon as possible. Return the valve to the ON position after refueling.
Reserve fuel range is about 7-10 miles (11-16 km).
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.
Fuel Tank Cap
Fuel Valve
OFF ON RES
Page 35
31
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is located on the right side of the vehicle.
F: Forward Gear N: Neutral R: Reverse
To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.
Indicator Lights
Indicator lights on the handlebar console illuminate when neutral or reverse gears are selected. The neutral indicator is green. The reverse indicator is amber.
Kick-Start Lever
If the battery is too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced.
1. Position the vehicle on a level surface. Lock the parking brake.
Place the transmission in neutral.
2. Fold out the kick-start lever on the left side of the ATV.
3. Make sure the stop switch and main key switch are on.
4. Place your foot on the kick-start. Thrust your heel downward to
crank the engine.
5. If the engine is cold, use the choke as outlined on page 36.
6. After the engine has started, fold the kick-start lever back into place.
Tip: A 10/12 mm wrench is provided in the tool kit for removing or installing the
lever. If not inst alled, make sure the rubber cap is installed on the kick-start shaft to protect the rider. Store the kick-start lever under the seat in the rear cab when not installed.
Gear
Selector
Reverse
Neutral
Page 36
32
OPERATION
Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gaso­line. No single action on your part is as important as following the pro­cedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 30. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level. See page 57. Add oil as needed to maintain the
level in the proper range.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 35.
6. Pull only light loads (if equipped with a hitch).
7. Change both the oil and the filter at 20 hours, 200 miles or one
month, whichever comes first.
WARNING
Page 37
33
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle. See page 7.
2. Do not allow anyone under 14 years of age to operate this vehicle.
Adult supervision is required for children under age 16. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
3. Never carry a passenger on this ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre­quently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills and operating condi-
tions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handle­bars while operating, and always keep both feet on the footrests.
8. Never consume alcohol or drugs before or while operating an ATV.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged ATV. After any rollover or accident, have
a qualified service dealer inspect the entire machine for possible damage.
11. Never operate the ATV on a frozen body of water.
12. Do not touch hot exhaust system components. Always keep com-
bustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
Page 38
34
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the opera­tion of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con­tacting your POLARIS dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow . Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.
Page 39
35
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
Item Remarks Page
Brake system/lever travel Ensure proper operation 26
62 Brake fluid Ensure proper level 29 Foot brake Ensure proper operation 27 Front suspension Inspect, lubricate if necessary 56 Rear suspension Inspect, lubricate if necessary 56 Steering Ensure free operation ­Tires Inspect condition and pressure 66 Wheels/fasteners Inspect, ensure fastener tightness 66 Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 30
57 Coolant level (if applicable) Ensure proper level ­Coolant hoses (if applicable) Inspect for leaks ­Throttle Ensure proper operation 25
92 Indicator lights/switches Ensure operation 24 Engine stop switch Ensure proper operation 24 Air filter, pre-filter Inspect, clean 68 Air box sediment tube Drain deposits whenever visible ­Headlight Check operation, apply POLARIS
dielectric grease when lamp is replaced
24
69
Brake light/tail lamp Check operation, apply POLARIS
dielectric grease when lamp is replaced
69
Riding gear Wear approved helmet, goggles, and
protective clothing
8
Page 40
36
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-venti­lated area.
2. Place the transmission in neutral.
3. Lock the parking brake.
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, move the choke lever
to the left until it stops.
Tip: The choke is fully on when the lever is com-
pletely to the left. The choke is off when the lever is completely to the right. The choke can be adjusted gradually, depending on how much choke is needed for starting.
7. Place the engine stop switch in the ON
position, then turn the main key switch on.
8. Do not press the throttle while starting the
engine. Squeeze the left brake lever.
Tip: The starter will not engage unless the rear brake is applied. Always
squeeze and hold the left brake lever before attempting to start the engine.
9. Press the start button.
Choke
Lever
Page 41
37
OPERATION
Starting the Engine
10. Activate the starter for a maximum of five seconds, releasing the button when the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before operating the vehicle.
11. If the engine does not start, release the start button, wait five sec­onds, then attempt to start again. Repeat this procedure until the engine starts.
12. If the engine slows or stops, move the choke lever half way to the right to allow proper engine warm-up. Vary the engine RPM slightly with the throttle to aid in warm-up.
13. When the engine idles smoothly, move the choke lever completely to the right.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently . A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained.
Tip: Water accumulation increases as outside temperature decreases.
If the oil level rises to the top of the sight glass, change the oil immedi­ately . Always operate the engine long enough to reach operating temper­ature, which reduces condensation.
Page 42
38
OPERATION
Driving Procedures
1. Wear a helmet and eye protection. See page 8.
2. Sit upright with both feet on the footrests and both hands on the handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the left brake lever and slowly depress the throttle with your right thumb to begin driving.
7. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
Page 43
39
OPERATION
Turning the Vehicle
To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turning in reverse.
Practice making turns at slow speeds before attempting to turn at faster speeds.
WARNING! Turning improperly can result in vehicle rollover. Never turn abruptly or at sharp angles. Never turn at high speeds.
Page 44
40
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. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.
4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
Sideways
skid
Turn in
direction of
skid
Page 45
41
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly ter­rain. Improper procedure could cause loss of control or rollover. When­ever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25° maximum).
3. Always check the terrain carefully before ascending any hill.
4. Never climb hills with excessively slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift body weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards.
8. Never go over the top of a hill at high speed.
9. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
25° Maximum
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42
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Shift body weight uphill.
4. Keep your feet on the footrests.
5. If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!
Page 47
43
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Avoid steep hills (25° maximum).
2. Shift body weight uphill.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling downhill can cause loss of control.
5. Squeeze the rear (left) brake lever gradually. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.
25° Maximum
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44
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. Squeeze the front (right) brake lever to stop the vehicle.
1. Lock the parking brake while keeping body weight uphill.
2. Leave the transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the vehi­cle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the rear (left) brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.
6. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill.
7. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly. Control speed with the rear brake until the vehicle is on more level ground.
8 ft. (2.4 m)
Page 49
45
OPERATION
Driving Through Water
Your ATV can operate through water with a maxi­mum recommended depth equal to the bottom of the footrests. Follow these pro­cedures when operating through water:
1. Determine water depths and current before entering water.
2. Choose a crossing
where both banks have gradual inclines.
3. Avoid operating
through deep or 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 52. The following areas need special attention: engine oil, transmission oil, rear gearcase oil, 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 72, 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
Page 50
46
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 haz­ards 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.
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47
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.
Page 52
48
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 LOAD 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 vehicle rollover.
NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) while towing a load on a level surface. V ehicle speed should never exceed 5 MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill .
WARNING
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49
OPERATION
Hauling Cargo
Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Always read and understand the load distribution warnings listed on the accessory rack and hitch warning labels.
Never carry cargo on the front of the vehicle. If the accessory rear rack is installed, cargo should be evenly distributed and mounted as low as possible on the rack.
Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, accessor ies, car go and weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
When operating over rough or hilly terrain, reduce speed and cargo or towed load to maintain stable driving conditions.
Maximum
70 lbs. (31.7 kg)
Page 54
50
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.
Page 55
51
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at POLARIS specifications to achieve optimal performance.
Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjustments should be performed by an authorized POLARIS dealer.
The vehicle compliance labels can be found on the frame tubing of the vehicle.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European direc-
tives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the lim­itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
Page 56
52
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 106.
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.
Page 57
53
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
WARNING! Improperly perf orming the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
Symbol Description
Ź 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)
D Have an authorized POLARIS dealer perform these services.
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54
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
Inspect and make
adjustments as needed.
See Pre-Ride Checklist on
page 35.
Front suspension - ­Rear suspension - ­Tires - ­Brake fluid level - ­Brake lever travel - ­Brake system - ­Wheels/fasteners - ­Frame fasteners - ­Engine oil level - ­Fuel Tank - Daily - Add Carbon Clean with each
fuel fill. See page 30.
Ź
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Ź Air box sediment
tube
- Daily - Drain deposits when visible
Headlamp/tail lamp
- Daily - Check operation; apply dielectric grease if replacing
Ź
E
Air filter, main element
- Weekly - Inspect; replace as needed
Ź
D
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Ź Engine oil change 20 H 1M 250 (400) Break-in oil and filter change Ź Front gearcase oil
(if equipped)
25 H 1 M 250 (400) Break-in oil level check
Ź Transmission oil 25 H 1 M 250 (400) Break-in oil level check
Ź
E
Engine breather filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
Ź 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
DEThrottle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
Page 59
55
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
DEChoke 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
Ź Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change
at 20 hours
Ź Oil filter change 100 H 6 M 1000 (1600) Replace with oil change Ź Front gearcase oil
(if equipped)
100 H 12 M 1000 (1600) Change fluid
Ź Transmission oil 100 H 12 M 1000 (1600) Change fluid
DEValve clearance 100 H 12 M 1000 (1600) Inspect; adjust
DEFuel 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
Ź Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/ pipe
100 H 12 M 1000 (1600) Inspect
DESpark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
DEIgnition Timing 100 H 12 M 1000 (1600) Inspect
Ź Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric grease to connectors subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out Idle speed - Adjust as needed
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
Page 60
56
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 52. Items not listed in the chart should be lubricated at the General Lubrication interval.
Item Lube Method
Engine Oil PS-4 Extreme Duty
10W-50 4-Cycle Oil
See page 57.
Brake Fluid DOT 4 Brake Fluid See page 29. Transmission Oil AGL Gearcase Lubricant
& Transmission Fluid
See page 60.
Rear Gearcase ATV Angle Drive Fluid See page 61. Front A-Arms U-Joint Grease Inspect; tighten fasteners; grease
(also after washing ATV or driving in water)
Front A-Arms
Page 61
57
MAINTENANCE
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. POLARIS recom­mends the use of POLARIS PS-4 Extreme Duty 10W -50 4-cycle engine oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or mix oil brands.
Oil Specifications
Oil Level
Maintain the oil level at the center of the sight glass. Do not overfill.
NOTICE: A rising oil level between checks in cool weather driving can indicate
contaminants such as gas or moisture collecting in the crankcase. If the oil level rises to the top of the sight glass, change the oil immediately.
1. Position the vehicle on a level surface.
2. View the oil level through
the sight glass on the right side of the vehicle.
3. Remove the fill plug and
add the recommended oil as needed.
4. Reinstall the fill plug
securely.
Lubricant Capacity D rain Plug Torque
PS-4 Extreme Duty 10W-50 4-Cycle Oil
41 oz. (1200 ml) 11 ft. lbs. (15 Nm)
Sight Glass
Fill Plug
Page 62
58
MAINTENANCE
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil.
NOTICE: If the ATV is left without oil in the system for extended periods, the oil
pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil. Do not allow the vehicle to be without oil overnight.
1. Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption.
2. Position the vehicle on a level surface.
3. Clean the area around the drain plug on the bottom of the engine
crankcase.
4. Run the engine for two to three minutes until warm. Stop the engine.
5. Place a drain pan beneath the engine crankcase and remove the
drain plug. Allow the oil to drain completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
6. Install a new sealing washer on the drain plug. The sealing surfaces
on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.
7. Reinstall the drain plug. Torque to specification.
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59
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. Using a clean, dry cloth, clean the filter sealing surface on the crankcase.
10. Lubricate the gasket on the new filter with a film of engine oil. Check to make sure the gasket is in good con­dition.
11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.
12. Remove the oil fill plug and add the recommended oil. Do not over­fill.
13. Reinstall the fill plug.
14. Start the engine and let it idle for one to two minutes.
15. Stop the engine and inspect for leaks.
16. Check the oil level and add oil as necessary to maintain the level at the center of the sight glass.
17. Discard used oil and filter properly.
Page 64
60
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Maintain the oil level between 1/4 and 3/4 on the sight glass. See page 98 for the part numbers of POLARIS products.
Transmission Oil Recommendations
Oil Check
1. Position the vehicle on a level surface.
2. View the oil level
through the sight glass.
3. Remove the fill plug and
add the recommended oil as needed.
4. Reinstall the fill plug.
Oil Change
The transmission drain plug is located on the bottom of the vehicle near the center.
1. Remove the fill plug.
2. Remove the transmission drain plug. Drain the oil into an appropri-
ate container. Discard used oil properly.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the recommended fluid.
5. Reinstall the fill plug.
6. Check for leaks.
Gearcase Lubricant Capacity Drain Plug Torque
Transmission AGL Gearcase Lubricant &
Transmission Fluid
18.6 oz. (550 ml)
18 ft. lbs.
(24 Nm)
Sight Glass
Fill Plug
Page 65
61
MAINTENANCE
Rear Gearcase Oil
Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52.
Maintain the oil level at the bottom of the check plug hole. We recom­mend the use of POLARIS ATV Angle Drive Fluid. Use of other oils may result in improper operation of components. See page 98 for the part numbers of POLARIS products.
Rear Gearcase Oil Recommendations
Oil Check
1. Position the vehicle on a level surface.
2. Remove the check plug and view
the oil level.
3. Remove the fill plug. Add the
recommended oil as needed.
4. Reinstall the fill plug. Torque to
specification.
5. Reinstall the check plug. T orque to
specification.
6. Check for leaks.
Oil Change
1. Remove the skid plate.
2. Remove the drain plug. Drain the oil into an appropriate container.
Discard used oil properly.
3. Clean and reinstall the drain plug with a new sealing washer . T orque
to specification.
4. Remove the fill plug and add the recommended gearcase oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the skid plate.
Gearcase Lubricant Capacity Fill Plug
Torque
Drain/Check Plug
Torque
Rear
Gearcase
ATV Angle Drive
Fluid
4 oz.
(120 ml)
25 ft. lbs.
(34 Nm)
18 ft. lbs.
(24 Nm)
Check Plug
Fill Plug
Page 66
62
MAINTENANCE
Brakes
Front Brake Inspections
The front (right lever) brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. This brake system is self­adjusting.
The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.
1. Always keep brake fluid at an adequate level. See page 29.
2. Check the brake system for
fluid leaks.
3. Check the brakes for excessive
travel or spongy feel.
4. Check the friction pads for
wear, damage and looseness. Replace the pads when the fric­tion material is worn to 1 mm.
5. Check the security and surface
condition of the disc.
1 mm
Page 67
63
MAINTENANCE
Brakes
Rear Brake Adjustments
The rear (left lever) brakes are mechanical brakes, acti­vated by moving the brake lever toward the handlebar. The foot brake is also a mechanical rear brake.
Adjust the rear brakes when brake lever travel reaches 2 1/2" (65 mm). Always adjust the brakes when there is no longer sufficient stopping ability at the specified lever travel setting.
1. Position the vehicle on a level surface.
2. Block the front wheels.
3. Place the transmission in neutral.
4. Using suitable stands, elevate the rear of the vehicle so the rear wheels are slightly off the ground.
5. Slowly tighten the hand brake wing nut while rotating the rear wheels with your hand. When you begin to feel resis­tance (drag) in the wheel rotation, loosen the wing nut one full turn.
6. Slowly tighten the foot brake wing nut until the foot brake lever arm begins to move. Loosen the wing nut 1/2 turn so it doesn't influence the hand brake adjustment.
7. Test the hand brake and the foot brake for proper operation.
2 1/2" (65 mm)
Hand Brake
Wing Nut
Foot Brake
Wing Nut
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64
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 to 1/4 inch (3-6 mm) toe out.
WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a level surface.
2. Set the handlebars in a
straight-ahead position and secure them in this position.
3. Place a chalk mark on the
center line of the front tires approximately 10 inches (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
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65
MAINTENANCE
Steering Assembly
The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.
Side Panel Removal
1. Remove the seat.
2. Remove the three fasteners securing the side panel to the vehicle.
3. Pull the side panel away from the vehicle.
Fasteners
Page 70
66
MAINTENANCE
Tires
Operating your A TV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 96 for recom­mended tire type, size and pressure.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com­ponent operations. All service must be performed by your authorized POLARIS dealer.
WARNING
1/8" (3 mm)
Page 71
67
MAINTENANCE
Tires
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in gear.
3. Stop the engine. Lock the parking brake.
4. Loosen the wheel nuts slightly.
WARNING! Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer.
5. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.
6. Remove the wheel nuts. 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.
3. Lower the vehicle to the ground.
4. Torque the wheel nuts to specification.
WARNING! Loose nuts could cause a tire to come off during operati on, which could result in an accident or rollover. Always ensure that all nuts are torqued to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos­ened for service.
Location Nut Torque
Front Wheel 27 ft. lbs. (37 Nm)
Rear Wheel 27 ft. lbs. (37 Nm)
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68
MAINTENANCE
Air Filter
1. Position the vehicle on a level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. Remove the seat.
5. Release the air box cover
clips, and remove the air box cover.
6. Loosen the clamp and
remove the air filter.
7. Remove the pre-filter from the main filter.
8. Wash the pre-filter in soapy water, then rinse and let dry.
9. Reinstall the pre-filter over the main filter. Replace the main filter if
needed.
10. Reinstall the air filter into the air box. T ighten the clamp, but do not
over-tighten as filter damage could occur.
11. Reinstall the air box cover and the seat.
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69
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.
Headlamp Replacement
To access the assembly from the front, remove the front cover and unplug the wiring harness. Remove the headlight assembly from the vehicle.
To access the headlight assembly without removing the front cover, reach up under the front cab.
1. Remove the rubber cover from the back of the head­light.
2. Rotate the socket counter-
clockwise and pull it away from the headlight assem­bly.
3. Remove the headlamp and
install the new headlamp.
4. Reinstall all components.
Taillight/Brakelight Lamp Replacement
1. Remove the taillight lens cover mounting screws.
2. Remove the lens cover.
3. Remove the lamp.
4. Apply dielectric grease to the socket and install a new lamp.
5. Test the light for proper operation.
6. Reinstall the lens cover.
Rubber
Cover
Socket
Page 74
70
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 96 for the recom­mended spark plug type and gap for your vehicle. Torque spark plugs to specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . See page 71.
CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
1. Remove the spark plug cap.
2. Using the special wrench
provided in the tool pouch, rotate the spark plug counterclockwise to remove it.
3. Reverse the procedure
for spark plug installation. Torque to specification.
Plug Condition Torque Specificati on
New Spark Plug 9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)
Spark Plug Cap
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71
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.
Page 76
72
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 ATV to a dealer before starting it, follow the steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the foot­rests.
2. Turn the fuel valve off.
3. Check the air box and dry any water.
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 neces-
sary, repeat the drying procedure.
11. T ake the ATV to your dealer for service as soon as possible, whether
you succeed in starting it or not.
12. If water has been ingested into the transmission, follow the proce-
dure on page 74 for drying.
Drain
Screw
Page 77
73
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester 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 arrester while the system is hot. Allow components to cool sufficiently before proceeding.
Use the following procedure to periodically remove accumulated carbon from the arrester screen.
1. Remove the three screws and remove the arrester from the end of the muffler.
2. Use a non-synthetic brush to clean
the arrester screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air.
3. Inspect the screen for wear and
damage. Replace if necessary.
4. Remove and inspect the gasket.
Replace a worn or damaged gasket.
5. Reinstall the gasket and arrester.
6. Torque screws to 50 in. lbs. (5.6 Nm).
WARNING
Screws
Page 78
74
MAINTENANCE
Constant Variable Transmission (CVT) System
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
The CVT 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 CVT system is intended for use on POLARIS products only. Do not install it in any other product.
• Always make sure the CVT housing is securely in place during operation.
CVT Drying
There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operat­ing.
1. Remove the CVT drain plug from the bottom of the CVT cover.
2. 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.
WARNING
Page 79
75
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your ATV may have either a sealed battery, which requires little mainte­nance, or a conventional battery . A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the termi­nals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.
WARNING
WARNING
Page 80
76
MAINTENANCE
Battery
Battery Removal
1. Remove the seat.
2. Disconnect the battery
hold-down strap.
3. On conventional batteries,
remove the battery vent tube.
4. Disconnect the black
(negative) battery cable first.
5. Disconnect the red
(positive) battery cable last.
6. Lift the battery out of the battery compartment. Be careful not to tip
a conventional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the vehicle.
Page 81
77
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 79 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 t ube (sealed bat-
teries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Secure the battery hold-down strap.
8. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
9. Reinstall the seat.
Page 82
78
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.
POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by char ging 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 98 for the part numbers of POLARIS products.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
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
Page 83
79
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 76.
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 77. 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.
WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufac-
turer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging.
Page 84
80
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 batt er y)
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% 1 1.5-12.0 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
Page 85
81
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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82
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:
• Wheel bearings
• Transmission seals
•Brakes
• Cab and body panels
• Labels and decals
• Electrical components
• Switches and controls If an informational or graphic label becomes illegible or comes off, con-
tact 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.
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83
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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84
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 81.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean fuel treatment or POLARIS Fuel Sta-
bilizer. 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. Stop the engine.
5. Turn the fuel valve off.
6. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 58.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Drain the sediment tube.
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85
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 52.
• Rear gearcase
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
Fog the Engine
Use POLARIS Engine Fogging Oil. Follow label directions carefully.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52.
Battery Storage
See pages 78-79 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV 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.
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86
MAINTENANCE
Transporting the Vehicle
Follow these procedures when trans­porting the vehicle.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the fuel valve off.
5. Secure the fuel cap, oil cap and
seat.
6. Remove the key to prevent loss
during transporting.
7. Always tie the frame of the ATV to
the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front bum­per, racks or handlebars.
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ADJUSTMENTS
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.
Accessory springs are available through your POLARIS dealer.
Adjuster
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ADJUSTMENTS
Handlebars
WARNING! 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 and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.
The handlebars can be adjusted for rider preference.
1. Remove the handlebar
cover.
2. Loosen (do not remove) the
four handlebar clamp 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. Tighten the front handlebar
clamp bolts first, then tighten the rear bolts. Torque to 25 ft. lbs. (34 Nm).
6. Reinstall the handlebar
cover . T ighten screws to 3.5 ft. lbs. (4.7 Nm).
3.5 ft. lbs. (4.7 Nm)
25 ft. lbs.
(34 Nm)
Cover
Handlebar
Bolts
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ADJUSTMENTS
Carburetor
Your POLARIS ATV is calibrated at the factory for optimal perfor­mance at altitudes ranging from zero to 8,000 feet (2400 m) and temper­atures above 15° F (-9° C). Refer to the specifications section beginning on page 96 for carburetor and jetting specifications.
Any jetting changes must be made only by an authorized POLARIS dealer. Always see your dealer if jetting changes are needed.
Tip: Continuous operation of the engine without proper jetting when required
can cause poor performance, overheating or engine damage. See your POLARIS dealer for more information about jetting the ATV for conditions in your area.
Carburetor/Engine Idle RPM Adjustment
If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.
1. Place the transmission in gear.
2. Lock the parking brake.
3. Start the engine and allow it to warm up for approximately five min­utes.
4. Turn the carburetor idle screw in (clockwise) to raise RPM. T urn the screw out (counterclockwise) to lower RPM.
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ADJUSTMENTS
Speed Control System
This vehicle is delivered in a limited mode to have a maximum speed at or below 20 MPH (32 km/h). The vehicle contains a means for limiting the maximum speed to 20 MPH (32 km/h) and 30 MPH (48 km/h) or less. The maximum unrestricted speed capability is 38 MPH (61 km/h) or less.
The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer's request, r emove or adjust any speed lim­iting devices.
Your POLARIS ATV has an adjustable throttle limiting screw. Speed limiting devices may be adjusted/removed only by consumers when they determine that their child is capable of handling the additional speed.
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ADJUSTMENTS
Speed Control System
Throttle Stop Speed Control System
The speed control system has two options for limiting speed. Adjusting the speed limit screw allows you to control vehicle speed between 0 and 30 MPH (48 km/h). This adjustment con­trols how far the throttle opens. To remove the speed limiting entirely and allow operation up to the maximum vehicle speed of 38 MPH (61 km/h), the speed limit bracket can be removed.
1. To adjust the speed limit
screw, loosen the jam nut.
2. Turn the screw inward to reduce the speed. Turn the screw outward to increase speed up to the 30 MPH (48 km/h) maximum. The throt­tle lever will stop against the speed control bracket at the maximum setting.
3. Tighten the jam nut after adjusting.
4. To allow the vehicle to operate to the maximum of 38 MPH (61 km/h), remove the bracket fastener on the throttle assembly and remove the bracket.
Bracket Fastener
Limiting Screw
Bottom Views of
Throttle Assembly
Jam Nut
Adjusted Below Maximum
Adjusted at Maximum
Bracket Removed
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ADJUSTMENTS
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 1/16" to 1/8" (1.5-3 mm) of freeplay is
achieved at the thumb lever . While adjusting freeplay, be sure to flip the throttle lever back and forth several times.
3. Tighten the lock nut and slide the boots over the cable adjuster until
they touch at the midpoint of the adjuster.
Lock Nut
Sleeve
Boot
Boot
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TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Tripped circuit breaker Reset the breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non-recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug(s) Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Overuse of choke Inspect, clean and/or replace spark plugs Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer
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94
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed
Possible Cause Solution
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s) Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer
Possible Rich Fuel Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer
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95
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s) Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean engine exterior; see your
POLARIS dealer
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96
SPECIFICATIONS
Phoenix 200
Maximum Weight Capacity 215 lbs. (98 kg) (includes weight of operator,
cargo and accessories) Dry Weight 395 lbs. (179 kg) Fuel Capacity 2.5 gal. (9.5 l) Engine Oil Capacity 41 oz. (1200 ml) Transmission Oil 18.6 oz. (550 ml) Rear Gearcase Oil 4 oz. (120 ml) Rear Rack Capacity 70 lbs. (31.7 kg) Hitch Tongue Weight Capacity 30 lbs. (13.6 kg) (Rear rack weight and tongue
weight not to exceed 30 lbs./13.6 kg) Hitch Towing Weight Capacity 300 lbs. (136 kg) Overall Length 65 in. (165 cm) Overall Width 42 in. (106.7 cm) Overall Height 42 in. (106.7 cm) Wheelbase 45 in. (114.3 cm) Ground Clearance 5.7 in. (14.5 cm) Minimum Turning Radius 65 in. (165.1 cm) unloaded Engine Type 4-Cycle, Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 196 cc Bore x Stroke 65 x 59 Alternator Output 210w @5000 rpm Compression Ratio 9.2:1 Full Stroke Carburetor 1 / 22 mm (VM Type) Pilot Jet 40 Main Jet 98 Air Screw 1 Turn Out Jet Needle 2MKNN-4 clip Ignition System DC CDI Ignition Timing 32q +/- 2q @ 3000 RPM Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm Driving System Type Constant Variable Transmission (CVT) Shift Type Side Lever (F/N/R) Drive Ratio, Front N/A Tires, Front 21x7-10 / 4 psi (27.6 kPa) Tires, Rear 20x10-9 / 4 psi (27.6 kPa) Front Suspension Dual A-Arm w/7 in. (17.8 cm) travel Rear Suspension Mono-Shock Swing Arm w/6.5 in. (16.5 cm)
travel
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