Polaris 2014 Sportsman 400 H.O. Owner's Manual

Read this manual carefully. It contains important safety information.

Operation is prohibited for those under 16 years of age.

Sportsman 400 H.O.

Owner's Manual

for Maintenance and Safety

This is an adult vehicle only.

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.

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® electric 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.

2

POLARIS® and SPOR TSMAN® are registered trademarks 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 inaccuracies. Any
reprinting 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 U.S.A.
2014 SPORTSMAN 400 H.O. / 400 H.O. SE Owner’s Manual
P/N 9924247

3

TABLE OF CONTENTS

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

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

Features and Controls. . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Emission Control Systems . . . . . . . . . . . . . . . 73

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 125

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 129

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 130

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 141

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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.

5

INTRODUCTION

Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.

• Never operate an ATV without proper instruction. Take a training course.

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

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

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

controlled 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

6

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

####

Engine Serial Number

Key Number

VIN

(front or rear frame)

7

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 [phone] 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 INFORMAT ION 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.

8

SAFETY

Safe Riding Gear

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

Helmet

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

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

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

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS
ATV any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.

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

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

10

SAFETY

Safety Warnings

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

Operating Without Instruction

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

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

Never permit a guest to operate the 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 an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.

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

WARNING

11

SAFETY

Safety 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

refueling is performed or where gasoline is stored.

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

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

and water and change clothing.

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

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.

12

SAFETY

Safety Warnings

Protective Apparel

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

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

Using Alcohol or Drugs

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

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

Carrying a Passenger

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

Never carry a passenger on this ATV.

13

SAFETY

Safety 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 overturn.

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

Operating on Public Roads

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

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

Operating at Excessive
Speeds

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

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

14

SAFETY

Safety 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 overturn.

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

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

Jumps and Stunts

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

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

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 51.

15

SAFETY

Safety Warnings

Descending Hills Improperly

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

• Always follow proper procedures for

traveling down hills as described in the
owner's manual. NOTE: A special technique
is required when braking while traveling
downhill. See page 53.

• Always descend a hill with the transmission

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

• Always check the terrain carefully before

descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean

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

Crossing Hillsides

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

If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 52.

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 54.

16

SAFETY

Safety Warnings

Stalling While Climbing a Hill

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

• Always maintain a steady speed when climbing
a hill.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the brakes.

• Lock the parking brake when fully stopped.

• Dismount on uphill side, or to either side if ATV is pointed straight uphill.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 54.

If the ATV begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.

• When fu lly stopped, apply the rear brake as well, and then lock the parking
brake.

• Dismount on uphill side, or to either side if ATV is pointed straight uphill.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 54.

Operating on Steep Hills

Operating on excessively steep hills could cause
an overturn.

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

17

SAFETY

Safety Warnings

Operating on Slippery Terrain

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

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

Operating in Unfamiliar Terrain

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

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

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

18

SAFETY

Safety Warnings

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 57.

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

Improper Tire Maintenance

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

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

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

Operating Over Obstacles

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

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 57.

Skidding or Sliding

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

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

19

SAFETY

Safety Warnings

Operating Through Deep Water

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

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

55):

• 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.

Improper Cargo Loading

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

• Never exceed the stated load capacity for this ATV.

• Cargo should be properly distributed and securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater

distance for braking.

• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.

(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).

• Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer. See page 59.

20

SAFETY

Safety Warnings

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 unless you have
independently verified that the ice is sufficiently thick to support the weight and
moving force of the A TV, you and your cargo, together with any other vehicles in
your party. Variances in snow depth and/or water currents may result in uneven
ice thickness. Always check with local authorities and residents to confirm ice
conditions and thickness over your entire route. ATV operators assume all risk
associated with ice conditions on frozen bod ies of water.

Poor Visibility

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

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

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

Hot Exhaust Systems

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

Unauthorized Use of the ATV

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

21

SAFETY

Safety Decals 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 tra ining 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

22

SAFETY

Safety Decals and Locations

Discretionary Warning

WARNING

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

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: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 485 lbs. (220 kg)

• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).

7177973

Hitch Capacity Label

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)

7174159

“No Passenger” Warning

WARNING

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

DEATH.

7175378

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.

NEVER operate this ATV if you are under age 16.

7175374

Discretionary

Warning

23

SAFETY

Safety Decals and Locations

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

7172563

Rack Warning, Front and Rear

WARNING

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

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

• Max Rack Loads: Front 90 lb s. (41 kg) Rear 180 lbs. (82 kg)

7172572

Reverse Override Warning/4X4 Caution

WARNING

Improper use of override button can lead to loss of control resulting in serious
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.

7175486

Tire Pressure/Load

Warning

General

Warning

“No Passenger”

Warning

Age 16

Warning

Rack

Warning

Rack

Warning

Clutch Cover

Warning

Hitch

Capacity

24

FEATURES AND CONTROLS

Switches

Mode/Reverse Override Switch

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

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

The override switch is also used to toggle through the modes of the rider
information center. See page 34.

Tip: The override switch will not function as a MODE switch if the transmission

is in reverse.

AWD Switch

Use the AWD switch to engage 4X4 or 2X4. See page 33. The vehicle
automatically engages AWD when operating in reverse if the AWD
switch is set to the AWD position.

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

Choke

AWD Switch

25

FEATURES AND CONTROLS

Switches

Engine Stop Switch

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

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

Main Key Switch

Use the main key switch to start the engine. See page 46 for starting
procedures.

Headlight 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
and the engine stop switch must be in the RUN position to operate the
headlights.

OFF OFFRUN

26

FEATURES AND CONTROLS

Throttle Lever

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

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

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

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 a
throttle release switch, 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 , t he engine wil l stop , and power to the rear wheels will
cease.

WARNING

27

FEATURES AND CONTROLS

Brake Lever

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

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

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

WARNING

28

FEATURES AND CONTROLS

Master Cylinder/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 in the master
cylinder before each ride.

1. Position the ATV on a level

surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window
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.

4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

WARNING

Master Cylinder

Indicator

Window

29

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then
squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

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

lever. It will return to its unlocked position.

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.

30

FEATURES AND CONTROLS

Auxiliary Foot Brake

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

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

The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, use the auxiliary foot
brake. Since this is a rear brake only, it will not be as ef fective as the all­wheel single lever system.

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

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

Brake Fluid Level

Check the brake fluid level
frequently for the auxiliary brake
system. The reservoir is located
under the seat on the left side of
the vehicle. Maintain the fluid
level between the maximum and
minimum marks.

WARNING

Auxiliary Foot Brake

Foot Brake Fluid

Reservoir

31

FEATURES AND CONTROLS

Fuel Valve

The fuel valve is located in the left
front wheel well.

OFF: For vehicle storage and when
transporting.

ON: For normal operation.

Choke

The choke assists in starting a cold
engine. Refer to the engine starting
procedure on page 46 for correct
choke and throttle settings during
starting.

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

This vehicle is equipped with a digital fuel gauge that will indicate a low
fuel condition. Refuel when the gauge indicates a low fuel condition.

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

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded
or unleaded gasoline with a minimum pump octane number of 87=(R+
M/2) octane. Do not use fuel with ethanol content greater than 10

percent, such as E-85 fuel.

OFF

ON

Fuel

Tank

Cap

Fuel

Valve

32

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

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

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

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
PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.

Gear

Selector

33

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The All Wheel Drive system is
controlled by the AWD switch.
When the switch is on 2X4, the
ATV is in two-wheel drive at all
times. When the switch is on
AWD, the ATV is in all wheel
drive and the A WD indicator light
in the instrument cluster will be
on.

When in AWD, the demand drive unit will automatically engage any
time the rear wheels lose traction. When the rear wheels regain traction,
the demand drive unit will automatically disengage.

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

is on. See page 24.

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

Engaging AWD

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

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

AWD

Switch

34

FEATURES AND CONTROLS

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. In addition to showing vehicle speed,
the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles as well as hours of
operation. It also includes a reverse speed limiter function that limits the
ATV's speed to approximately 7-9 MPH (11-14 km/h). Refer to page 24
for additional information.

NOTICE: High water pressure may damage ATV components. Wash the A T V

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

damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.

Rider

Information

Center

Speedometer

Needle

Speedometer

35

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All
segments will light up for 2.5 seconds at start-up. If the instrument
cluster fails to illuminate, a battery over-voltage may have occurred and
the instrument cluster may have shut off to protect the electronic
speedometer. If this occurs, take the ATV to your POLARIS dealer for
proper diagnosis.

1. Gear Indicator - This

indicator displays gear
shifter position:
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park

2. AWD Indicator - This

indicator illuminates
when the AWD switch
is in the AWD position.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

that the ATV is operating at an RPM too low to keep the battery
charged. It may also occur when the engine is at idle and high
electrical load (lights, cooling fan, accessories) is applied. Drive at a
higher RPM or recharge the battery to clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.

8. Check Engine W arning Indicator - The word HOT displays if the

engine overheats. Do not operate the ATV if this warning appears.
Serious engine damage could result.

9. Mode Indicator

1

2

345

6

7

9

8

36

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse
override button is also the MODE button. See page 24. The transmission
cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

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

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM
from day to day may be normal because of changes in humidity,
temperature and elevation.

37

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode.
To exit the diagnostic mode, turn the key switch off and on. Any
movement of the tires will also cause the gauge to exit the diagnostic
mode.

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD
coil (only on models with switchable AWD). This screen is for
informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge. This screen is for informational purposes
only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 39.

The service interval is programmed at 50 hours at the factory.

39

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

or OFF appears in the Rider Information Center, depending on your
preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours
quickly.

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

6. When the desired setting is displayed, wait until the wrench icon

stops flashing. The new service interval is now programmed.

40

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display
either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

(MP).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode
has been set.

41

OPERATION

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

Break-In Period

The break-in period for your new POLARIS ATV is the first 20 hours of
operation. No single action on your part is as important as following the
procedures for a proper break-in. Careful treatment of a new engine and
drive components will result in more efficient performance and longer
life for these components.

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

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

WARNING

42

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 31. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level on the dipstick. See page 81. Add oil if

necessary to maintain the level between the safe and add marks.

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

familiarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 45.

6. Pull only light loads.

7. Change both the oil and the filter at 25 hours.

8. Check fluid levels of transmission and all gearcases after the first 25

hours of operation and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

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

If a belt fails, always clean away all debris when replacing the belt.

43

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

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

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

3. Never carry a passenger on this ATV.

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

run in an enclosed area.

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

emergency situations (if service brakes become inoperable).

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

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

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

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

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

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

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

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

Always maintain proper tire pressure.

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

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

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

independently verified that the ice is suf ficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.

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

combustible materials away from the exhaust system.

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

prevent unauthorized use.

44

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.

45

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 27

90
Brake fluid Ensure proper level 28
Auxiliary brake Ensure proper operation 30
Front suspension Inspect, lubricate if necessary 79
Rear suspension Inspect, lubricate if necessary 79
Steering Ensure free operation ­Tires Inspect condition and pressure 93
Wheels/fasteners Inspect, ensure fastener tightness 93

94
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 31

81
Coolant level (if applicable) Ensure proper level 88

89
Coolant hoses (if applicable) Inspect for leaks ­Throttle Ensure proper operation 26

117
Indicator lights/switches Ensure operation 24
Engine stop switch Ensure proper operation 25
Air filter, pre-filter Inspect, clean 95
Air box sediment tube Drain deposits whenever visible ­Headlamp Check operation, apply POLARIS

dielectric grease when lamp is
replaced

25
98

Brake light/taillight Check operation, apply POLARIS

dielectric grease when lamp is
replaced

101

Riding gear Wear approved helmet, goggles, and

protective clothing

8

46

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well­ventilated area.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

6. Do not use the choke if starting a warm engine. Excessive use of the

choke can cause the spark plug to become wet fouled.

7. If the engine is cold, pull the

choke knob out until it stops.

Tip: The variable choke is fully on

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

8. If the knob doesn't stay where

positioned, increase the
tension by rotating the tension
adjusting nut clockwise.

9. Move the engine stop switch to RUN.

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

Tension

Adjusting Nut

47

OPERATION

Starting the Engine

11. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

12. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.

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

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

13. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water
accumulation increases as outside temperature decreases.

48

OPERATION

Driving Procedures

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

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

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

4. Shift the transmission into gear.

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

6. Release the parking brake.

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

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

49

OPERATION

Turning the Vehicle

Your ATV is equipped with
a solid rear axle, which
drives both rear wheels
equally at all times. This
means that the wheel on the
outside of the turn must
travel a greater distance
than the inside wheel when
turning and the inside tire
must slip traction slightly.

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

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

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

50

OPERATION

Driving on Slippery Surfaces

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

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

2. Slow down when entering slippery areas.

3. Engage AWD before wheels begin to lose traction.

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

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

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

5. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.

Sideways

skid

Turn in direction

of skid

51

OPERATION

Driving Uphill

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

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

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

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

5. Keep both feet on the footrests.

6. Shift your weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.

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

25° Maximum

52

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

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

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

53

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Shift body weight uphill.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause
loss of control.

5. Squeeze the brake lever gradually. Applying the brakes too firmly
may cause the rear wheels to lock, which could result in loss of
control.

54

OPERATION

Turning Around on a Hill (K-Turn)

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

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

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

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

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

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

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

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

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

8 ft. (2.4 m)

55

OPERATION

Driving Through Water

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

1. Determine water depths and
current before entering
water.

2. Choose a crossing where

both banks have gradual
inclines.

3. Avoid operating through

deep or fast-flowing water.

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

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 74. The following areas need
special attention: engine oil, transmission oil, demand drive fluid, 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 104,
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

56

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.

57

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 button 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.

58

OPERATION

Hauling Cargo

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

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

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

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

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

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

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

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

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

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

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34

kg) and/or front cargo loads are above 37 lbs. (17 kg).
Vehicle should never exceed 10 MPH (16 km/h) while towing a load on a level

surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads
in rough terrain, while cornering, or while ascending or descendin g a hill.

WARNING

59

OPERATION

Hauling Cargo

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

Cargo weight should be evenly
distributed (1/3 on the front rack
and 2/3 on the rear rack) and
mounted as low as possible.

NEVER exceed 50 MPH (80
km/h) when rear cargo loads are
above 75 lbs. (34 kg) and/or
front cargo loads are above 37
lbs. (17 kg).

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

Do not obstruct the headlight beam with cargo.
Use low forward gear when hauling or towing heavy cargo to extend

belt life.

Towing Loads

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

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

not exceed the rear rack capacity.

• The total load (operator, accessor ies, car go and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding

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

1/3

2/3

Maximum

4" (10 cm)

60

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 PARK.

3. Lock the parking brake.

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

5. Turn the fuel valve off.

61

WINCH GUIDE

These safety warnings and instructions apply if your vehicle came
equipped with a winch or if you choose to add an accessory winch to
your vehicle.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially
designed synthetic rope. The term “winch cable” will be used for either
unless noted otherwise.

Winch Safety Precautions

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the
winch.

5. Always keep body, hair, clothing and jewelry clear of the winch
cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 70.

7. Always keep the area around the vehicle, winch, winch cable and
load clear of people (especially children) and distractions while
operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch
are not being used.

9. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided
by this wrapped cable allows the drum to pull on the winch cable
and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to
hold the vehicle in place during winching. Use wheel chocks if
needed.

WARNING

62

WINCH GUIDE

Winch Safety Precautions

11. Always align the vehicle and winch with the load directly in front of
the vehicle as much as possible. Avoid winching with the winch
cable at an angle to the winching vehicle’s centerline whenever
possible.

12. If winching at an angle is unavoidable, follow these precautions:

A. Look at the winch drum occasionally . Never let the winch cable “stack”

or accumulate at one end of the winch drum. Too much winch cable at
one end of the winch drum can damage the winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 68 to feed

and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the
winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s
rated capacity.

15. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.

16. Never touch, push, pull or straddle the
winch cable while winching a load.

17. Never let the winch cable run through
your hands, even if wearing heavy
gloves.

18. Never release the clutch on the winch
when the winch cable is under load.

19. Never use the winch for lifting or
transporting people.

63

WINCH GUIDE

Winch Safety Precautions

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Take your winch
to your dealer for service if this occurs.

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage
to winch components.

24. Unplug the remote control from the vehicle when the winch is not in
use to prevent inadvertent activation and use by unauthorized
persons.

25. Never grease or oil the winch cable. This will cause the winch cable
to collect debris that will shorten the life of the cable.

64

WINCH GUIDE

Winch Operation

Read the Winch Safety Precautions in the preceding pages before using
your winch.

Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change you r winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able
to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls
for any signs of damage or parts in need of repair or replacement
before each use. Pay particular attention to the first 3 feet (1 meter)

of winch cable if the winch is being used (or has been used) for lift­ing an accessory plow assembly. Promptly replace any worn or

damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s

park brake and/or park
mechanism to hold the vehicle
in place during winching. Use
wheel chocks if needed.

WARNING

Hook Strap

65

WINCH GUIDE

Winch Operation

4. Always use the hook strap when
handling the hook.

WARNING! Never put your fingers into
the hook. This could lead to SEVERE
INJURY.

A. Attach the hook itself onto the

load or use a tow strap or chain
to secure the load to the winch
cable.

Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WARNING! Never use a recovery strap when winching due to the excessive
energy that can be released if the winch cable breaks. This can result in
SEVERE INJURY or DEATH. See the Shock Loading section on page 70.

B. Never hook the winch cable back onto itself. This will damage the

winch cable and may result in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent
SEVERE INJURY or DEATH in the event of failure. For your safety, always
replace POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the

winching vehicle. This will help the spooling of the winch cable and
reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a

tow strap to avoid damaging the tree during winch operation. Sharp
cables and chains can damage and even kill trees. Please remember
to TreadLightly® (treadlightly.org).

E. Before operating the winch, be sure

that the safety latch on the winch
cable hook is fully seated when the
load is attached.

F. Never operate your winch with a

damaged hook or latch. Always
replace damaged parts before using
the winch.

NO YES

NO

YES

66

WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’ s pulling
capacity. Always be sure that at least five (5) full turns of winch
cable are wrapped around the winch drum at all times. The friction
provided by this wrapped cable allows the drum to pull on the
winch cable and move the load.

8. Read and adhere to the following information for winch damping to
ensure safe winch use.

A. In order to absorb energy that could be released by a winch cable

failure, always place a “damper” on the winch cable. A damper can be
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.

B. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

C. On a long pull, it may be necessary to stop winching so that the

damper can be repositioned to the new mid-point of the winch cable.
Always release the tension on the winch cable before repositioning the
damper.

D. Avoid being directly in line with the winch cable whenever possible.

Also, never permit others to stand near or in line with the winch cable
during winch operation.

9. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or
worn.

67

WINCH GUIDE

Winch Operation

11. The ONLY time a winch-equipped vehicle should be moving when
using the winch is when that vehicle itself is stuck. The winch­equipped vehicle should NEVER be in motion to “shock” load the
winch cable in an attempt to move a second stuck vehicle. See the
Shock Loading section on page 70. For your safety, always follow
these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch

cable.

B. Align the winch cable as close as possible to the winching vehicle’s

centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the

direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the
winch cable to a suspension component, brush guard, bumper or
cargo rack. Vehicle damage may result. Instead, attach the winch to
a strong portion of the vehicle frame or hitch.

68

WINCH GUIDE

Winch Operation

13. Extensive winching will run down the battery on the winching
vehicle. Let the winching vehicle’s engine run while operating the
winch to prevent the battery from running low if winching for long
periods.

14. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.

15. After winching is complete, especially if winching at an angle, it
may be necessary to re-distribute the winch cable across the winch
drum. You will need an assistant to perform this task.

A. Release the clutch on the winch.
B. Feed out the winch cable that is unevenly bunched up in one area.
C. Re-engage the winch clutch.
D. Have an assistant pull the winch cable tightly with about 100 lbs. (45

kg) of tension using the hook strap.

E. Slowly winch the cable in while your assistant moves the end of the

winch cable back and forth horizontally to evenly distribute the winch
cable on the drum.

F. Doing this reduces the chances of the winch cable “wedging” itself

between lower layers of winch cable.

69

WINCH GUIDE

Winch Cable Care

For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your
authorized POLARIS dealer.

WARNING! Use of worn or damaged cable could lead to sudden failure and
SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or
loose parts including mounting hardware. Never use the winch if
any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn

or kinked winch cable.

A. A kinked winch cable made of

wire rope is shown at right. Even
after being “straightened out,”
this cable has already been
permanently and severely
damaged. Promptly discontinue
use of a winch cable in this
condition.

B. A kinked winch cable made of

wire rope that has been
“straightened out” is shown at
right. Even though it may look
usable, the cable has been
permanently and severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use of a winch cable
in this condition.

C. A winch cable made of

synthetic rope should be
inspected for signs of fraying.
Replace the cable if fraying is
observed (shown at right).
Promptly discontinue use of a
winch cable in this condition.

D. Also replace the winch cable if there are fused or melted fibers. Such

an area of the synthetic rope will be stiff and appear smooth or glazed.
Promptly discontinue use of a winch cable in this condition.

A

B

C

70

WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic,

or “shock” loading. Shock loading may tension a winch cable beyond its strength
and cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both
wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never
take up slack in the winch cable by moving the winching vehicle in
an attempt to move an object. This is a dangerous practice. It gener­ates high winch cable loads that may exceed the strength of the
cable. Even a slowly moving vehicle can create large shock loads in
a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).

This puts extra load on the winch, winch cable, and generates
excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an

object with a winch produces shock loading of the cable even when
towing at slow speeds. Towing from a winch also positions the
towing force high on the vehicle. This can cause instability of the
vehicle and possibly lead to an accident.

71

WINCH GUIDE

Shock Loading

4. Never use recovery straps with your winch. Recovery straps are
designed to stretch and can store energy. This stored energy in the
recovery strap is released if a winch cable fails making the event
even more hazardous. Similarly, never use elastic “bungie” cords
for winching.

5. Never use the winch to tie down a vehicle to a trailer or other
transportation vehicle. This type of use also causes shock loading
that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads
produced by the winch motor when operated from a stationary
vehicle. Always remember that the winch and winch cable ar e NOT
designed for shock loading.

72

WINCH GUIDE

Winch Maintenance and Service Safety

WARNING! Improper or lack of winch maintenance and service could lead to

SEVERE INJURY or DEATH. Always follow all winch instructions and warnings
in this manual.

1. Always inspect your winch before each use. Inspect for worn or
kinked winch cable. Also inspect for worn or loose parts including
mounting hardware.

2. Permit your winch motor to cool down prior to servicing your

winch.

3. Never work on your winch without first disconnecting the battery

connections to prevent accidental activation of the winch

4. For your safety, always replace POLARIS winch parts (including

the cable) with genuine POLARIS replacement parts available at
your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other

winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade

polymer rope such as can be purchased in a hardware store.
Although they may look similar, they are NOT alike. A polymer
rope not designed for winch use will stretch and store excessive
energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release
all of the stored energy. This will increase the chances of SEVERE INJURY or
DEATH.

73

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 regu lated by 43 CFR 420.
V iolations are subject to monetary penalties. Federal reg ulations 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 emissions label is located on the right frame tube.

Electromagnetic Interference

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

Emissions Label

74

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 141.

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. 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.

75

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

WARNING! Improperly performing 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.

76

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

-

Make adjustments as need
ed. See Pre-Ride Checklist
on page 45.

Front suspension - ­Rear suspension - ­Tires - ­Brake fluid level - ­Brake lever travel - ­Brake system - ­Wheels/fasteners - ­Frame fasteners - ­Engine oil level - -

Ź

E

Air filter, pre-filter - Daily - Inspect; clean often; replace

as needed

Ź Air box sediment

tube

- Daily - Drain deposits when visible

Coolant - Daily - Check level daily, change

coolant every 2 years

Headlight/taillight/
worklight

- Daily - Check operation; apply
dielectric grease if replacing
lamps

Ź

E

Air filter, main
element

- Weekly - Inspect; replace as needed

Recoil housing - Weekly - Drain water as needed,

check often if operating in wet
conditions

Ź

D

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

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

Ź

E

Engine breather
filter (if equipped)

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

Ź Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change
Ź Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check
Ź Rear 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

77

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

cables, etc.

Shift linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust

D Steering 50 H 6 M 310 (500) Lubricate

Ź Front suspension 50 H 6 M 310 (500) Lubricate
Ź Rear suspension 50 H 6 M 310 (500) Lubricate

Carburetor float
bowl

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

prior to storage

DEThrottle Cable/

Release Switch

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

replace if necessary

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

Cooling system 50 H 6 M 500 (800) Inspect coolant strength

seasonally; pressure test
system yearly

Ź Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
Ź Oil lines and

fasteners

100 H 6 M 1000 (1600) Inspect for leaks and loose

fittings

Ź Demand drive fluid

(normal use)

100 H 12 M 1000 (1600) Change fluid

Ź Rear 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 Radiator (if

applicable)

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

surfaces

Ź Cooling hoses (if

applicable)

100 H 12 M 1000 (1600) Inspect for leaks

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

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

78

MAINTENANCE

Periodic Maintenance Chart

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)

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

79

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 74. Items not listed in
the chart should be lubricated at the General Lubrication interval.

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

Item Lube Capacity at

Fluid Change

Inspection Procedure

Engine Oil PS-4 5W-50

4-Cycle Oil

2 qt. (1.9 l) Maintain level in safe range

on dipstick. See page 81.

Brake Fluid DOT 4 Brake Fluid --- Maintain level between fill

lines. See page 28.

Transmission Oil AGL Gearcase

Lubricant &
Transmission Fluid

32 oz. (948 ml) Maintain level at bottom of fill

hole threads. See page 85.

Demand Drive
Fluid
(Front Gearcase)

Demand Drive
Fluid

9 oz. (265 ml) Maintain level at bottom of fill

hole threads. See page 86.

Front Prop Shaft
Yoke

U-Joint Grease --- Grease fittings (3 pumps

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

Front Prop Shaft Yoke

80

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil.
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-

50 4-cycle oil or a similar oil for this engine. Oil may need to be
changed more frequently if POLARIS oil is not used. Always use 5W­50 oil. Follow the manufacturer's recommendations for ambient
temperature operation. See page 129 for the part numbers of POLARIS
products.

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.

Lubricant Capacity Drain Plug Torque

PS-4 5W-50 4-Cycle Oil 2 qts. (1.9 l) 14-17 ft. lbs. (19-23 Nm)

81

MAINTENANCE

Engine Oil

Oil Level

Access the oil dipstick and fill tube
from the left side of the ATV.

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 is over the
full/safe mark, change the oil
immediately.

1. Position the vehicle on a level
surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the
engine.

3. Remove the dipstick. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

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

Dipstick

Safe

Add Oil

{

Safe Range

82

MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 74. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drain
plug.

5. Place a drain pan under the oil
tank.

6. 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.

7. Install a new sealing washer on
the drain plug. The sealing
surfaces on drain plug and
crankcase should be clean and
free of burrs, nicks or scratches.

8. Reinstall the drain plug. Torque
to 14-17 ft. lbs. (19-23 Nm).

9. Disconnect the lower oil
delivery hose and remove the
screen fitting from the oil tank.
Clean the fitting. The fitting threads must be sealed with LOCTITE

PST 505 or PTFE seal tape.

10. Reinstall the screen fitting and rotate the fitting clockwise a
minimum of 2 1/2 turns into the tank threads. Continue to rotate the
fitting until the nipple of the fitting aligns with the mark on the tank.
Do not over-tighten. Maximum torque for the screen fitting is 25 ft.
lbs. (34 Nm).

11. Reattach the oil line.

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

83

MAINTENANCE

Oil and Filter Change

12. Place shop towels beneath the oil
filter. Using an oil filter wrench,
turn the filter counter-clockwise
to remove it.

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

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

15. Install the new filter and rotate it clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.

16. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the
crankcase. The sealing surfaces on the drain plug and crankcase
should be clean and free of burrs, nicks or scratches.

17. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

18. Remove the dipstick.

19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.

Tip: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initiall y.

20. Place the transmission in PARK.

21. Lock the parking brake.

22. Prime the oil pump using the procedure on page 84. Then stop
the engine and inspect for leaks.

23. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.

24. Dispose of used filter and oil properly.

84

MAINTENANCE

Oil and Filter Change

Oil Pump Priming

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

1. Clamp or pinch off the vent line
approximately 2" (5 cm) from
the oil tank, between the end of
the oil tank vent fitting and the
vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and
ready for operation.

Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.

Clamp

Pressure

Relief Slit

Tank

2"

(5 cm)

85

MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 74. Maintain the
oil level at the bottom of the fill plug hole threads. See page 129 for the
part numbers of POLARIS products.

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

Transmission Oil Recommendations

Oil Check

1. Position the vehicle on a level
surface.

2. Remove the fill plug. Check the

oil level.

3. Add the recommended fluid as

needed to bring the level to the
bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to

specification.

Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

AGL Gearcase Lubricant &

Transmission Fluid

32 oz.

(946 ml)

20-25 ft. lbs.

(27-34 Nm)

20-25 ft. lbs.

(27-34 Nm)

Drain Plug

Fill Plug

Fill

Level

Fill Plug

86

MAINTENANCE

Transmission Oil

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.

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

4. Add the proper amount of the recommended oil.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Dispose of used oil properly.

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals
outlined in the Periodic Maintenance Chart beginning on page 74.
Maintain the fluid level at the bottom of the fill hole threads. See page
129 for the part numbers of POLARIS products.

Fluid Recommendations

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

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Front

Gearcase

Demand Drive Fluid 9 oz.

(265 ml)

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

11 ft. lbs.

(15 Nm)

Drain Plug

Fill

Plug

Fill Level

87

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Check

1. Position the vehicle on a level surface. Remove the fill plug. Check
the fluid level.

2. Add the recommended demand drive fluid as needed to bring the

level to the bottom of the fill hole threads.

3. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

Fluid Change

1. Position the vehicle on a level surface. Remove the fill plug. Place a
drain pan under the demand drive unit.

2. Remove the drain plug. Allow the fluid to drain completely.

3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).

4. Add the recommended fluid. See page 86 for capacity. Maintain the

fluid level at the bottom of the fill hole threads.

5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

6. Check for leaks. Dispose of used fluid properly.

88

MAINTENANCE

Cooling System

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

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

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

POLARIS recommends the use of POLARIS Antifreeze 60/40 premix
or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. POLARIS Antifreeze is already premixed
and ready to use. Do not dilute with water. See page 129 for the part
numbers of POLARIS products.

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

Recovery Bottle Coolant

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

1. Remove the left side panel.
See page 92.

2. Maintain the coolant level

between the minimum and
maximum marks on the
bottle (when the fluid is
cool).

3. Add coolant as needed.

Recovery

Bottle

89

MAINTENANCE

Cooling System

Radiator Coolant

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

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

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

1. Open the front box cover.

2. Remove the access panel
screws. Squeeze the outer
edges of the panel inward to
remove the panel.

3. Remove the pressure cap.

4. Using a funnel, slowly add
coolant through the radiator
filler neck.

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

6. Reinstall the access panel and secure the front box cover.

Radiator

Cap

90

MAINTENANCE

Brakes

Hand Brake

The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self­adjusting.

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

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 28.

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 brake pads when
they are worn to 3/64" (1 mm).

5. Check the security and surface condition

of the disc. Clean any grease using a
recommended brake cleaner or alcohol.
Do not use spray lubricants or other petroleum-based products. If
you discover any damage (cracks, excessive corrosion, warping) see
your dealer for service before operating.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 30.

3/64" (1 mm)

91

MAINTENANCE

Toe Alignment

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

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

1. Position the vehicle on a
level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straight­edge instead of string.

4. Measure the distance

from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/16"-1/8" (2-3 mm) more than the front measurement on
each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6
mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your POLARIS dealer for

service.

String

Stand

2

1

FRONT

92

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. Grasp the rear of the side panel near the rear cab. With a firm
motion, pull the panel outward to disengage the side panel from the
grommet.

3. Pull the panel downward and rearward to remove it.

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.

3. Remove the footwell.

Step 1 Step 2 Step 3

Screws

Rivets

93

MAINTENANCE

Tires

Operating your ATV with worn tires, improperly inflated tires, non-standard tires
or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 130 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.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. 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. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

WARNING

1/8" (3 mm)

94

MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in PARK.

2. Lock the parking brake.

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

4. Install the wheel nuts and finger-tighten them.

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

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

Wheel Nut Torque Specifications

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

Nut Type Nut Torque

Lug Nut (Aluminum
Wheels)

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

2-Piece Flange Nut
(Steel Wheels)

27 ft. lbs. (37 Nm)

95

MAINTENANCE

Air Filter

1. Remove the seat.

2. Release the air box cover
clips, and remove the air box
cover.

3. Loosen the clamp and
remove the filter.

4. Remove the fabric type pre­filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.

5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.

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

7. Reinstall the air box cover and the seat.

Main Filter

Pre-Filter

Breather

Filter

96

MAINTENANCE

Breather Filter/Hose

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

1. Remove the left side panel. See page 92.

2. Remove the hose clamps from the filter and pull the filter out of the
hoses.

3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace a damaged or
clogged filter.

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

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

NOTICE: Operation of your vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for
service.

97

MAINTENANCE

Fuse Replacement

If the engine stops or will not
start, or if you experience other
electrical failures, a fuse may need
replacement. Locate and correct
any short circuits that may have
caused the blown fuse, then
replace the fuse. Spare fuses are
provided in a compartment on the
top of the access door.

1. Open the front box cover.

2. Remove the suspect fuse from
the fuse panel. If the fuse is
blown, install a new fuse with
the same amperage.

3. Secure the front box cover.

Fuse Panel

Fuses

5or61520 20

98

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.

Headlight Lamp Replacement

When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.

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

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the pod.

4. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

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

5. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring.

6. Turn the lamp counter-clockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp. Make

sure the tab on the lamp locates properly in the housing.

8. Reassemble the pod.