Polaris ATV 2002 Owner's Manual

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WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

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

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Indicates a potential hazard that could result in serious injury or death.

WARNING

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We’ve created a web site, just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

Page 5

WELCOME

Thank you for choosing Polaris, and welcome to our world-wide family of P olaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Vict ory motorcycl es.

We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine we’ve ever produced.

Follow the instructions and recommendations in this Owner’s Manual for safe and enjoyable operation of your vehicle. Your Owner’s Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

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

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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

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ATTENTION!

This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 16 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!

Read this manual thoroughly referring to the various areas which are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment.

SAFETY TRAINING

When you purchased this vehicle your dealer offered a hands-on safety training course covering all aspects of ATV safety. In addition, you were provided with certain printed material which instructs you on safe operating procedures.

You should review this information on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result in

SEVERE INJURY OR DEATH.

NOTE: Illustrations used in this manual are for general representation only. Your model may differ.

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TABLE OF CONTENTS

Vehicle Identification Numbers 6..............

Safety 7 - 42.................................

Understanding Warnings 7.........................

Key Safety Issues 8...............................

Decals and Locations 12...........................

Operator Safety 22................................

Features and Controls 43 - 65.................

Controls 43.......................................

Features 58......................................

Operation 66 - 70.............................

Pre Ride Inspection 66............................

Vehicle Break-In Period 67.........................

Starting the Engine 70.............................

Carrying Loads 72................................

Noise Emission Control System 75............

Riding 76 - 87................................

Pre Ride Inspection 76............................

Safe Riding Tips 77...............................

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TABLE OF CONTENTS

Maintenance and Lubrication 88 - 168..........

Periodic Maintenance Schedule 88..................

Lubrication Recommendations 94...................

Maintenance Record 100..........................

Cooling System 101...............................

Lubrication 104...................................

Filter Systems 127................................

Adjustments 130..................................

Lights 146........................................

Spark Plugs 153..................................

Water Service 154................................

Spark Arrestor 155................................

Recoil Housing 157................................

PVT 158.........................................

Battery 161.......................................

Side Panel Removal 164...........................

Cleaning and Storage 165..........................

Trouble Shooting 169 - 172....................

Warranty 173 - 175...........................

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VEHICLE IDENTIFICATION NUMBERS

Record these numbers from your ATV in the spaces provided.

1. Frame VIN (found on the lower left side of the frame tube)

2. Engine Serial Number (Right front side of engine crankcase)

Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key.

The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recovery and identification of your ATV.

Dealer Imprint

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SAFETY

Understanding Warnings

The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

Indicates a potential hazard that could result in serious injury or death.

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

WARNING

CAUTION

NOTE

“NOTE:” will alert you to important information or instructions.

Indicates a situation that may result in damage to the machine.

CAUTION

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SAFETY

Key Safety Issues

Protect Your Sport

Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others. We also advise you to strictly follow the recommended maintenance

program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are t horoughly inspected at various intervals.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of P olaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles

including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

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SAFETY

Key Safety Issues

SERIOUS INJURY OR DEAT H can result if you do not follow these instructions:

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

procedures described.

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

course. Beginners should receive training from a certified instruc-

tor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate this ATV unless the guest has read

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

S Always avoid operating an ATV on any paved surfaces, including

sidewalks, driveways, parking lots and streets.

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

dirt or gravel one.

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

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

S Never consume alcohol or drugs before or while operating this

ATV.

S Never operate at excessive speeds. Always travel at a speed which

is proper for the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV each time you use it to m ake sure it is in

safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

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

footrests of the ATV during operation.

S Always go slowly and be extra careful when operating on unfamil-

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

S Never operate on excessively rough, slippery or loose terrain. S Always follow proper procedures for turning as described in this

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

S Always have the ATV checked by an authorized Polaris dealer if it

has been involved in an accident.

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SAFETY

Key Safety Issues

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

abilities. Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

S Always follow proper procedures for going down hills and for brak-

ing on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

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

described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn t he ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

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

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

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

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

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

such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

S Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maximum depth (pg. 84), go slowly, balance your weight carefully avoiding sudden m ovements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.

S Wet brakes may have reduced stopping ability. Test your brakes

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

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SAFETY

Key Safety Issues

S Always be sure there are no obstacles or people behind you when

you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

S Always use the size and type tires specified in this manual. Always

maintain proper tire pressure as described i n this manual.

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

cessories.

S Never exceed the stated load capacity for an ATV. Cargo should be

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

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

prevent unauthorized use or accidental starting.

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

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a P olaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive m aintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage i ntervals.

NOTE:

The addition of certain accessories including (but not limited to) mowers, blades, tires, sprayers, or large racks may change the handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved by Polaris.

Familiarize yourself with their function and affect on the ATV.

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SAFETY

Safety Decals and Locations

NOTE:

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your P olaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.

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SAFETY

Safety Decals and Locations

7079083

E1997, 2000

IF OWNER’S MANUAL IS MISSING, CONT ACT YOUR POLARIS DEALER FOR A REPLACEMENT.

WARNING

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SAFETY

Safety Decals and Locations

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SAFETY

Safety Decals and Locations

F Never operate this ATV on HILLS steeper than 25 degrees

To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

25°

F REVERSE operation can be dangerous even at low speeds.

Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

F Use OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

F PARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

7079085

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.

7078253

UNDER

WARNING

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SAFETY

Safety Decals and Locations

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SAFETY

Safety Decals and Locations

(Refer to your Owner’s Manual Supplement for your vehicle’s specifications.)

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

TIRE PRESSURE (PSI): FRONT ___ REAR ___

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

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

Read Owner’s Manual for more detailed loading information

(on rear of seat)

WARNING

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SAFETY

Safety Decals and Locations

ATTENTION

D Operation of this

vehicle without the filter element will severely damage the engine.

D Clean air filter often, more

frequent cleaning required in dusty conditions

(Under Seat)

Moving part s haz ard under belt-clut ch guar d. To prevent serious injur y, do not operat e vehicl e with guard remov ed.

Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

NO STEP

7078689

D Specific carburetor jetting

and adjustments are required depending on temperature and altitude. See your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet (5_ to 27_

C. at 0-900 meters).

7079901

WARNING

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SAFETY

Safety Decals and Locations

DO NOT TOW FRO M RACK OR BUMPER. Vehicle damage or t ipover m ay res ult c ausing sev ere injury or death. Tow only f rom tow hook s or hitch.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs

7070021

WARNING

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SAFETY

Safety Decals and Locations

ALL WHEEL

DRIVE

SWITCH

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

7079780

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

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

PRINTED IN U.S.A.

7077185

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

TRAILER MAX. WEIGHT 850 LBS.

HITCH MAX. VERTICAL WEIGHT 30 LBS.

POIDS MAX. DE REMORQUE 386 KG.

POIDS MAX. VERTICAL D’ATTACHE 14 K G.

7079604

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

OVERRIDE

SWITCH

7079906

AWD Models

2WD Models

7077542

TRAILER MAX WEIGHT: 1225 LBS. (556 KG) ON LEVEL GROUND 850 LB S. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)

7072533

Chain Freeplay Is Important. Adjust Freeplay to 3/16″ -- 3 / 8 ″ DO NOT Overtension. See Owner’s Manual.

Torque Nut on E ccentric Bolts:

To 30 Ft. Lbs.(For models without a hitch). To 60 Ft. Lbs. (For models with ahitch.

7078572

WARNING

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

NOTE: Your machine will not have all the decals depicted on this page.

The decals found on your machine will depend on the model you own.

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SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

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

2. Eye Protection

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

3. Gloves

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

4. Boots

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

5. Clothing

To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

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SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner’s Manual.

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

POTENTIAL

HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age

can lead to severe injury or death of the child. Even though a child may be within the age group for which some

ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

HOW TO AVOID THE

HAZARD

No one under 16 should operate a Polaris ATV.

WARNING

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SAFETY

Operator Safety

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your

passenger. HOW TO AVOID THE

HAZARD

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

WARNING

Indicates a potential hazard that could result in serious injury or death.

WARNING

Page 27

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways. WHAT CAN

HAPPEN

The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the A TV, and may cause the vehicle to go out of control.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.

WARNING

Page 28

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway,

even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets,

roads and highways.

WARNING

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SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye

protection and protective clothing. WHAT CAN

HAPPEN

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

Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

HOW TO AVOID THE

HAZARD Always wear an approved helmet which fits properly. You should also wear: eye protection (goggles or face shield);

gloves; boots; long-sleeved shirt or jacket; and long pants.

WARNING

Page 30

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE

HAZARD

Never consume alcohol or drugs before or while driving this ATV.

POTENTIAL

HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can

result in an accident. HOW TO AVOID THE

HAZARD

Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience.

WARNING

Page 31

SAFETY

Operator Safety

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to

show off.

WARNING

Page 32

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV . WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure

the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

POTENTIAL

HAZARD

Removing hands from handlebars or feet from footrests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce your ability to control the A TV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.

HOW TO AVOID THE

HAZARD

Always keep both hands on the handlebars and both feet on the footrests of your A TV during operation.

WARNING

Page 33

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar

terrain. WHAT CAN

HAPPEN

You can come upon hidden rocks, bumps, or holes, without enough time to react.

Could result in the ATV overturning or going out of control. HOW TO AVOID THE

HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain.

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

WARNING

Page 34

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to use extra care when operating on excessively

rough, slippery or loose terrain. WHAT CAN

HAPPEN

Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.

HOW TO AVOID THE

HAZARD

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

Always be especially cautious on these kinds of terrain.

WARNING

Page 35

SAFETY

Operator Safety

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in

the Owner’s Manual. See page 78 . Practice turning at low speeds before attempting to turn at

faster speeds. Do not turn at excessive speed.

POTENTIAL

HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills

than on level surfaces or small hills. HOW TO AVOID THE

HAZARD

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

Practice on smaller hills before attempting large hills. Never operate A TV on hills steeper than 25_.

WARNING

Page 36

SAFETY

Operator Safety

POTENTIAL HAZARD Climbing hills improperly . WHAT CAN HAPPEN Could cause loss of control or cause A TV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described

in the Owner’s Manual. See pages 80 through 83. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over

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

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

WARNING

Page 37

SAFETY

Operator Safety

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause A TV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as

described in the Owner’s Manual. See page 82. NOTE: A special technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any hill.

Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the

vehicle to lean sharply to one side. Go straight down the hill where possible.

WARNING

Page 38

SAFETY

Operator Safety

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause A TV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have

mastered the turning technique as described in the Owner’s Manual on level ground. See page 83. Be very careful when turning on any hill.

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

hill:

Always follow proper procedures as described in the Owner’s Manual.

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

WARNING

Page 39

SAFETY

Operator Safety

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN

HAPPEN

Could result in ATV overturning.

HOW TO AVOID

THE

HAZARD Maintain steady speed when

climbing a hill. Ifyouloseallforward

speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock

parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the A TV around and remount, following the procedure

described in the Owner’s Manual. See page 83.

WARNING

Page 40

SAFETY

Operator Safety

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV

to overturn. HOW TO AVOID THE

HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as

large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures

as described in the Owner’s Manual.

POTENTIAL

HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV . You may also regain traction unexpectedly, which may cause the

ATV to overturn. HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

WARNING

Page 41

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control,

which could lead to an accident. HOW TO AVOID THE

HAZARD

Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg 84), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.

Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

POTENTIAL

HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in

severe injury. HOW TO AVOID THE

HAZARD

When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

WARNING

Page 42

SAFETY

Operator Safety

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

uneven tire pressure. WHAT CAN

HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE

HAZARD

Always use the size and type tires specified in the Owner’s Manual Supplement for this vehicle.

Always maintain proper tire pressure as described in the Owner’s Manual Supplement.

POTENTIAL

HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this

vehicle may cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE

HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

WARNING

Page 43

SAFETY

Operator Safety

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo

improperly. WHAT CAN

HAPPEN

Could cause changes in vehicle handling which could lead to an accident.

HOW TO AVOID THE

HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely

attached. Reduce speed when carrying cargo or pulling a trailer.

Allow greater distance for braking. Always follow the instructions in the Owner’s Manual for

carrying cargo or pulling a trailer. See pages 72 through

74.

POTENTIAL

HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the A TV and/or the operator

break through the ice. HOW TO AVOID THE

HAZARD

Never ride your ATV on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

WARNING

Page 44

SAFETY

Operator Safety

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV

to overturn. HOW TO AVOID THE

HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as

large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures

as described in the Owner’s Manual.

POTENTIAL

HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV . You may also regain traction unexpectedly, which may cause the

ATV to overturn. HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

WARNING

Page 45

SAFETY

Operator Safety

After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage.

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

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

Indicates a potential hazard that could result in serious injury or death.

WARNING

CAUTION

Keep combustible materials away from exhaust system. Fire may result.

Page 46

CONTROLS AND FEATURES

Controls

Engine Electrical Switches

1. Override Switch (Reverse Speed Limiter)

- This vehicle is equipped with a reverse speed limiter system. To obtain additional power while backing up, depress the override button. NOTE: The override switch also allows activation of Demand 4 Drive (All Wheel Drive) in reverse, if Demand 4 Drive switch is on.

2. Main Switch - To start the engine, slide the stop switch to the center “run” position and turn the main key switch clockwise past the “on” position. Release the key when the engine starts.

3. Engine Stop Switch - The engine will not start or run when the switch is in its “off” position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the m ain switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights. To stop the engine, slide the stop switch right or left to the “off” position.

WARNING

Activating the override button while throttle is open can cause loss of control resulting in severe injury or death.

RUN OFFOFF

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

Page 47

CONTROLS AND FEATURES

Controls

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released.

This vehicle i s equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the operator releases the throttle lever.

Choke

Refer to the engine starting procedure on page 70 for correct choke and throttle settings during starting.

Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.

Always check the lever for free movement and return before starting the engine and occasionally during riding.

WARNING

Page 48

CONTROLS AND FEATURES

Controls

Brakes

The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only.

Always test brake lever travel and reservoir 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.

Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a spongy brake lever can result in loss of

braking. Loss of braking could cause an accident.

WARNING

Page 49

CONTROLS AND FEATURES

Controls

Front and Rear Brakes

The brake fluid in the master cylinder , which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (1) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. NOTE: When checking the fluid level, the ATV must be on level ground the the handlebars straight. If the fluid level is low add DOT 3 (PN 2870990) only.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

WARNING

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of severe injury.

WARNING

Page 50

CONTROLS AND FEATURES

Controls

Parking Brake

Setting the Parking Brake

1. Squeeze the left hand brake lever two or three times and hold it.

2. Push the park brake lock (2) into the notches on the master cylinder body. Release the brake lever.

3. To release the parking brake lock, squeeze the brake lever . It will return to its released position.

Important Safeguards

S The parking brake may relax when left on for a long period of time.

This could cause an accident.

S Do not leave the vehicle on a hill depending on the parking

brake for more than five minutes.

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

on a hill or park the ATV in a side hill position.

Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated.

WARNING

Page 51

CONTROLS AND FEATURES

Controls

Auxiliary Brake

Your Polaris ATV has an auxiliary brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative.

If the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding. Aggressively applying the rear brake when backing down a hill may cause rear tip over.

Brake Flu id L evel

It will be necessary to check the brake fluid level for the auxiliary brake system. The reservoir is located under the seat or near the foot brake. The fluid should be kept between the maximum and minimum marks.

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

WARNING

Page 52

CONTROLS AND FEATURES

Controls

Engine Fuel and Oil System

Fuel System

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual Supplement for tank capacity. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

The fuel valve is located on the left side of the front fender and has three positions:

OFF: For vehicle storage and whenever transporting.

ON: For normal operation. RES: For reserve supply in

the event of main supply exhaustion.

NOTE: There is about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply.

Always return valve to “on” position after refueling machine.

Engine Fuel Safety/Fuel/Filter

The P olaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of

operation or annually. Do not attempt to clean the fuel filter.

OFF

RES

Page 53

CONTROLS AND FEATURES

Controls

Engine Fuel and Oil System

Gasoline is highly flammable and explosive under certain conditions.

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

ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not over fill the tank. Do not fill the tank neck. S If you get gasoline on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area. Gaso-

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

S Shut off fuel valve whenever the ATV is stored or parked.

The engine exhaust from this product con-

tains chemicals known to cause cancer,

birth defects or other reproductive harm.

WARNING

Page 54

CONTROLS AND FEATURES

Controls

Engine Fuel and Oil System

On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine. R efer to your Owner’s Manual Supplement to determine the type of engine your vehicle has. The tank capacity is 2 quarts (1.9 l).

On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

To avoid serious engine damage always top off the oil level when refueling.

CAUTION

Page 55

CONTROLS AND FEATURES

Controls

Automatic Transmission Gear Selector

Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your machine’s shift pattern.

The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter. The transmission selector lever has three or four positions: high forward; reverse; neutral; and low forward or forward; reverse; and neutral. C heck your Owner’s Manual Supplement for specification.

NOTE: To ext e nd belt life, use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of time.

Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problem see your dealer.

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

CAUTION

Page 56

CONTROLS AND FEATURES

Controls

Manual Shift

The engine can only be started with the transmission in neutral.

Turn the key to “on” and ensure the stop switchisintherun position.

The neutral indicator light should be on. If it is not, shift the foot pedal down ( or up and down, if in Reverse) to find neutral. Refer to the gear shift pedal illustrated on this page.

Once the vehicle is in neutral, start the engine by engaging the starter.

Brake Start

This model also has a brake start feature t hat can be used when it is difficult to find neutral. To activate, pull on the LH brake lever and engage the starter.

Gear Shift Pedal

To shift to a higher gear, raise the pedal one full stroke.

To downshift, depress the pedal one full stroke.

Page 57

CONTROLS AND FEATURES

Controls

Shift Pedal

The gear shift pedal is above the left floorboard. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence. The pedal automatically returns to the horizontal position when released.

The Xpedition has five forward gears (1, 2, 3, 4, and 5). To upshift to a higher gear, put the toe of your boot under the gear shift pedal and raise the pedal one full stroke. To downshift, step on the gear shift pedal and depress the pedal one full stroke.

Shifting Gears

Start the engine and let it warm up, follow this procedure:

1. With the transmission in neutral, hold the brake lever.

2. With the throttle closed, raise the gear shift pedal one full stroke to shift into first gear.

3. Release the brake lever and increase engine speed by gradually opening the throttle.

4. When speed increases, release t he throttle and shift to 2nd gear by raising the gear shift pedal one full stroke.

5. Repeat sequence 4. to progressively upshift to 3rd, 4th and 5th (top) gear.

6. To downshift, reverse sequence 4. Remember to release the throttle each time you shift to the next lower gear.

POTENTIAL HAZARD Shifting gears without releasing the throttle. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always release the throttle when shifting gears.

WARNING

Page 58

CONTROLS AND FEATURES

Controls

Shifting to Reverse

With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control. Depress the gear shift pedal one stroke. The reverse indicator light will come on. Slowly release the brake lever and press throttle control lightly.

Important Safeguards

S Always back slowly avoiding excessive speed and do not use the

reverse speed override switch system unless additional power is required for vehicle movement.

S Avoid turning at sharp angles in reverse. S Avoid backing on steep inclines.

Light Switches and Indicator Lights

Be careful when operating in reverse. Make certain your path is free of obstacles or and bystanders. Risk of a tip over is greatly increased on hillS. Avoid backing on hills or inclines whenever possible. Tipovers could result causing severe injury or death.

WARNING

This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

WARNING

Page 59

CONTROLS AND FEATURES

Controls

Shifting From Reverse to Forward

Be sure machine is completely stopped. Hold the brake lever, raise gear shift pedal one full stroke to engage forward gear. NOTE: neutral is bypassed when shifting from reverse to 1st gear. To engage neutral, depress gear shift pedal one full stroke from the 1st gear position.

To Decelerate

When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be certain the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.

POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control,

an accident and injury. It could also cause engine or drive train damage.

HOW TO AVOID THE

HAZARD

Make certain the engine has sufficiently slowed before shifting to a lower gear.

WARNING

Page 60

CONTROLS AND FEATURES

Controls

Recoil Starter

If the battery is weak and cannot start the engine, use of the recoil starter (A) located on the right side of the machine will allow vehicle operation until repairs can be made.

Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting.

1. Be certain your vehicle is on a level surface and the parking brake isset. Seepage74.

2. Take the machine out of gear.

3. Grasp the recoil starter tightly and pull slightly until the starter mechanism engages.

4. Pull the rope abruptly to start the engine.

Do not extend the starter rope so far that it stops This will cause damage to the recoil assembly.

Make sure the manual start handle is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

CAUTION

Page 61

CONTROLS AND FEATURES

Features

Exclusive AWD System (All Wheel Drive)

Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off” the ATV is in 2 wheel drive at all times. When the switch is “on” the ATV is in Demand 4 Drive and the AWD indicator(2) will light.

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

NOTE: The override switch also allows activation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on.

There is no limit to the length of time the vehicle may remain in Demand 4 Drive.

The Demand 4 Drive switch may be turned on or off while the vehicle is moving. If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction.

NOTE: Select AWD models do not have an AWD switch. These models are continuously in All Wheel Drive.

Do not switch on Demand 4 Drive if the rear wheels are spinning. This may cause severe drive shaft and hub damage.

CAUTION

Page 62

CONTROLS AND FEATURES

Features

Exclusive AWD System (All Wheel Drive)

Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on.

Disengaging Wheel Hubs

When backing up while in Demand 4 Drive and then going forward, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again.

You can tell if only one front hub is engaged if the handlebars pull to one side. If both front wheel hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

NOTE: If the hubs remain engaged after following these instructions return the ATV to your dealer for service.

Switches

The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: The lights will not work unless the key is in the on position and shut off switch is in the “run” position.

If both hubs were engaged and only one released during operation, loss of control could result. If you experience hub engaging symptoms, use the above disengaging technique before proceeding. Failure to disengage front hubs as directed above could result in severe injury or death.

WARNING

Page 63

CONTROLS AND FEATURES

Features

Indicator Lights

Each P olaris ATV has indicator lights. The configuration of t hese lights differs with individual models and not every model is equipped with all the lights. The information in your Owner’s Manual Supplement and in the information on this page will help you identify the lights on your machine and their function.

1 Transmission Neutral (Green) 2 Transmission Reverse (Yellow) 3 Oil Warning (Red) On 2 cycle models, this light indicates a low oil

level. 4 High Temp (Red) (Will light only if engine overheats) 5 All Wheel Drive (Red) (located on the throttle control) Refer to page 58. 6 High Beam Indicator (Blue) (located on the LH switch on models equipped with Hi-Lo beam lights)

With engine running, verify function of indicator lights each time ATV is used.

NOTE: The taillight is on whenever the main switch (key) is in the on position. Turn the key off to prevent battery drain.

Page 64

CONTROLS AND FEATURES

Features

Electronic Speedometer

Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilometers as well as hours of operation. The speedometer also includes a reverse speed limit function that limits the ATV’s speed in at approximately 7 to 9 mph. Refer to page 43 for additional information.

To display each mode, press the button on the face of the speedometer once to “toggle” through the functions. Each function will be displayed as follows:

Miles 00000.0 M Trip Miles 000.0 M Hours 00000.0 H

To reset Trip Miles:

1. Toggle to Trip Miles

2. Hold down button approximately 4 seconds.

The speedometer also has additional features accessed through a sub-menu. These features are:

S Programmable service reminder based on hours S Programmable service reminder based on distance S Change distance measurement from Miles to Kilometers or vice

versa.

Each service reminder is set to zero and must be programmed to activate the feature. One or both service reminders can be set. Whichever setting is reached first, the reminder will turn on in the LCD window.

Do not wash the electronic speedometer with a high pressure washer. Wash the unit by hand or with a garden hose. High water pressure may allow water to enter the speedometer and cause damage to the electronic components

CAUTION

Page 65

CONTROLS AND FEATURES

Features

Electronic Speedometer

When the programmed hours are reached, SEr hr will light; when the programmed distance is reached, SErdIS will light. Each time the vehicle is started, the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next service interval.

Accessing Sub-menu Features

There are two methods for accessing the sub menu:

1. Press and hold the button and turn the power on

2. Press and hold the button for 8 seconds Hold the button until the display shows POLArS then release the

button. The speedometer is now in the sub-menu. To display each mode, press the button once to scroll through the four available functions. Each function will be displayed as follows:

Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE

Changing Distance Measurement

1. Access the sub-menu

2. Select COnvrT and release the button. If the last digit in the odometer display is K, the current measurement is kilometers; if the last digit is M, distance is being measured in miles.

To Set Service Hours

1. Access the sub--menu

2. Toggle to SET hr, then release the button.

3. In 3 seconds, the LCD will display 5 digits, with the left--most digit flashing.

4. Within 4 seconds, press and release t he button to change the digit. Once the digit is changed once, the button may be held to scroll through the digits from 0 to 9.

5. After the digit has been selected, do not push the button. After 4 seconds the next digit will flash.

Page 66

CONTROLS AND FEATURES

Features

Electronic Speedometer

Setting Service Hours (cont.)

6. Repeat step 4 and 5 to program the digits for the service interval selected. (i.e. for service interval of 50 hours set the display to show: 00050 H)

7. To save the changes press and hold the button when any one of the digits is flashing.

8. The display will change to DOnE. At this time release the button and the changes are now saved.

TO CHECK WHEN SERVICE IS DUE BY HOURS

Using the 50--hour service setting example from above, the speedometer will take the 50--hour setting and add it to the value of the hour--meter. This will be the value displayed when the operator checks when service is due for the ATV. For example, the hour meter reading is 132 hours, and t he service interval was set for 50 hours, the 5--digit display will show 182 hours.

1. Access the sub--menu

2. Toggle to SET hr , then release the button

3. In 3 seconds, the LCD will display 5 digits, with the left--most digit flashing. As in the example above, the display would show 00182 H.

4. Either turn the power off or not touch the button for 35 seconds to maintain the current settings.

Page 67

CONTROLS AND FEATURES

Features

Electronic Speedometer

To Set Service Distance

Same as setting Service Hours, but toggle to SET dIS.

To Check When Service Is Due By Distance

Same as setting Service Hours, but toggle to SET dIS.

To Clear The Service Reminder From The Display

The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval. When this is done the display will return to the normal menu showing odometer, trip meter and hour meter.

If the service interval isn’t reprogrammed the reminder will be displayed each time the speedometer is powered up; again pushing the button can clear the display.

Indicates a potential hazard that could result in serious injury or death.

WARNING

Page 68

CONTROLS AND FEATURES

Features

Auxiliary Power Outlet

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights.

On select models, an outlet is located on the front headlight pod. To determine if your vehicle i s equipped with auxiliary power outlet,

please check your Owner’s Manual Supplement. Accessory outlets are available for all models. Contact your Polaris

dealer for more information.

Page 69

OPERATION

PreRideInspection

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (includes

auxiliary brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches

6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter pins

8. Drive chain - condition and slack; refer to drive chain adjustment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual looseness in

any area

11. Loose parts - visually inspect vehicle for any damaged components

or loose nuts/bolts or fasteners

12. Operators helmet, goggles and clothing

13. Engine coolant - (Liquid Cooled Models Only) check for proper

level at the recovery bottle

You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

WARNING

Page 70

OPERATION

Break-In Period

2-Cycle Engines

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

1. Mix 12.8 ounces of injection oil to four gallons (or 16 ounces to 5 gallons) of gasoline in a suitable gas can. Fill the fuel tank as outlined on page 49.

2. Fill the oil tank with Polaris injection oil.

3. Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions.

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 66.

Use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

CAUTION

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

CAUTION

Page 71

OPERATION

Break-In Period

After the break in period the oil injection system provides the necessary engine lubrication without the need for pre-mixed fuel.

After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that t he oil pump is functioning properly. If the level has not dropped, see your dealer for oil pump bleeding and repeat the pre-mix procedure.

Fill the oil tank when you refuel your ATV. If you don’t serious engine damage could result.

CAUTION

Page 72

OPERATION

Break-In Period

4-Cycle Engines

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

1. Fill fuel tank with either unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir l evel indicated on dipstick. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will give you 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 all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 66.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 200 miles.

Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

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

CAUTION

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Page 73

OPERATION

Starting the Engine

Procedure for Starting a Cold Engine

1. Place the transmission in neutral and reset the parking brake.

2. Turn the fuel tank valve to ON.

3. Sit on the vehicle.

4. Pull the choke out all the way.

5. Turn the engine stop switch to RUN.

6. Turn the ignition key past the “ON” position to engage the starter.

NOTE: the choke is on “FULL” when the knob is pulled out all the way. The choke is “OFF” when the knob is pushed in. This is a variable choke and can be adjusted gradually, depending on how much choke is needed for starting.

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

8. Activate the starter for a maximum of five seconds, releasing t he key or button when the vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until engine starts.

Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors.

WARNING

You must allow your vehicle adequate warm up time before operating or engine damage could result.

CAUTION

Page 74

OPERATION

Starting the Engine

After the Engine Starts

1. If the engine slows or stops, use of the choke at half way in will allow proper engine warm up.

2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in.

Cold Weather Operation - 4 Cycle Engines

Polaris offers the following kits for cold weather operation: Oil Tank Cover, Engine Heater and Oil Tank Heater . These kits redu ce moi sture accumulation in the oil tank when the ATV is operated in freezing temperatures.

If you use your ATV all year round, it is important to check your oil level frequently. A rising oil level could indicate the accumulation of water in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained.

Water accumulation increases as outside temperature decreases. The cold weather kits not only reduce moisture accumulation, but the

heaters provide quicker warm-ups and easier starting. See your dealer for more information on cold weather operation and

what kit will work best for your driving habits.

Page 75

OPERATION

Carrying Loads

Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Never exceed the weights specified in your Owner’s Manual Supplement.

Maximum trailer weight - 850 lbs.(386 kg); maximum vertical hitch weight - 30 lbs.(14 kg). Select models may tow up to 1225 (556 kg) on level ground only with a maximum vertical hitch weight of 35 lbs. (16 kg). Refer to your Owner’s Manual Supplement to determine your machine’s capabilities. Know your machine before your ride.

Maximum grade while trailer towing - 15°. Do not tow any trailer on a grade steeper than 15°.

If your machine is equipped with a front rack, take care when loading. Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.

Use of low forward gear is recommended in heavy pulling situations to extend belt life.

Page 76

OPERATION

Carrying Loads

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

Important Safeguards

To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below:

REDUCE SPEED AND ALLOW GREATER DISTANCE

FOR BRAKING WHEN CARRYING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the

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

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which m ay require backing downhill.

S ALL LOADS MUST BE SECURED BEFORE MOVING

VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

WARNING

Page 77

OPERATION

Carrying Loads

S LOADS MUST BE CARRIED 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. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

S OPERATE ONLY WITH STABLE AND SAFELY AR-

RANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your ATV.

S EXTREME CAUTION MUST BE USED when operating

with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE REC-

OMMENDED SPEEDS. Vehicle should never exceed 10 mph ( 16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

Page 78

NOISE EMISSION CONTROL

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair , or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or

(2) the use of the vehicle after such device or element of design has been removed or rendered i noperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING:

1. Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air induction system.

3. Replacement of any vehicle parts with parts not in compliance with federal regulations.

4. Lack of proper maintenance.

S Do not touch exhaust system components. Serious burns can re-

sult.

S Be especially careful when traveling through tall grass. The poten-

tial for fire exists.

USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your model, see the Owner’s Manual Specification Supplement that came with your machine.

CAUTION

Remember, exhaust system components are very hot during and after use of ATV. Serious burns can result if hot components are touched.

Page 79

RIDING

PreRideInspection

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (includes auxiliary brake)

4. Throttle - check for free operation and closing

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

6. Engine stop switch - check for proper function

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

8. Drive chain - condition and slack; refer to drive chain adjustment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual looseness i n any area

11. Loose parts - visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners

12. Operators helmet, goggles and clothing

13. Engine coolant - (Liquid Cooled Models Only) check for proper level at the recovery bottle

You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

WARNING

Page 80

RIDING

Safe Riding Tips

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

2. After starting the engine and allowing it to warm up, shift the transmission into gear.

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

4. Release the parking brake.

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

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

Indicates a potential hazard that could result in serious injury or death.

WARNING

Page 81

RIDING

Safe Riding Tips

Making Turns

Practice making turns at slow speeds.

Polaris ATVs are 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.

Avoid turning at sharp angles in reverse as tipover and severe injury may result.

WARNING

Page 82

RIDING

Safe Riding Tips

Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:

1. Slow down when entering slippery areas.

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

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

4. Driving with Demand 4 Drive (All WheelDrive) engagedcan assist in controlling the vehicle in slippery areas.

5. Never apply brakes during a skid. Complete loss of ATV control can result.

6. Do not operate on excessively slippery surfaces if possible to avoid.

7. Always reduce speed and use additional caution.

Severe damage to drive train may occur if the Demand Drive is engaged while the wheels are spinning.

CAUTION

Failure to exercise care when operating the ATV on slippery surfaces can be dangerous.

Loss of tire traction and vehicle control can result in an accident, including an overturn.

WARNING

Page 83

RIDING

Safe Riding Tips

Traveling Uphill

25_ Maximum

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills (25_ maximum).

2. Keep both feet on the footrests.

3. Transfer your weight forward.

4. Proceed at a steady rate of speed and throttle opening.

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

Indicates a potential hazard that could result in serious injury or death.

WARNING

Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

WARNING

Page 84

RIDING

Safe Riding Tips

Sidehilling

Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always:

1. Slow down.

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

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

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

Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

WARNING

Page 85

RIDING

Safe Riding Tips

Traveling Downhill

Whenever descending a hill, always:

1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in

the event loss of normal service brakes occurs.

Do not travel at excessive speeds. It is dangerous and can cause loss of vehicle control and tipping, resulting in severe injury or death.

WARNING

Page 86

RIDING

Safe Riding Tips

Turning Around On A Hill

8’

Uphill

If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

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

2. Leave transmission in forward and shut off engine.

3. Dismount on left or uphill side of ATV.

4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).

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

6. Lock the parking brake and remount ATV from the uphill side, maintaining body weight uphill.

7. Restart engine with transmission still in forward, release parking brake, and proceed slowly, controlling speed with the service brake, until ATV is on reasonably level ground.

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death.

WARNING

Page 87

RIDING

Safe Riding Tips

Crossing Streams

Your Polaris ATV can operate through water up to maximum recommende d depths reaching the footrests. Before fording streams always:

1. Determine water depths and current.

2. Choose a crossing where both banks have gradual inclines.

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

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

S Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maximum depth, go 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.

NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart beginning on page 88. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

If your vehicle becomes immersed, and it is impossible to take it to a dealer before starting, follow the steps described on page 154. It is still important the vehicle be serviced by your dealer at the first opportunity.

Page 88

RIDING

Safe Riding Tips

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches.

Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.

WARNING

Page 89

RIDING

Safe Riding Tips

Backing Up

1. Avoid backing up on steep inclines.

2. Always back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

6. Never activate override button while throttle is open. Loss of control may result.

NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed. Manual shift models (Xpedition) do not have a reverse speed limiter or an override.

Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

CAUTION

Page 90

RIDING

Safe Riding Tips

ParkingonanIncline

Whenever the Vehicle is Parked

1. Turn the engine off.

2. Place the transmission in gear or in park.

3. Set the parking brake.

4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

5. Shut off fuel supply.

Indicates a potential hazard that could result in serious injury or death.

WARNING

Page 91

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart on the following pages.

Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

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

" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty. Pl ease refer to your owner ’s manual supplement to determine if this applies to your vehicle.

Due to the nature of the adjustments marked with a J on the

following chart

, it is recommended that service be performed by an

authorized Polaris dealer.

CAUTION

Page 92

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles

When Remarks

Brake System Pre-ride Pre-ride Pre-ride inspection item Auxiliary Brake Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride in-

spection item Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bolts,

fasteners

Pre-ride Pre-ride Pre-ride inspection item

Injector Oil Level (2-Cycle)

Pre-ride Pre-ride Check when refueling

"LAir Filter - Pre-Clean-erPre-ride Pre-ride Inspect-Clean

Coolant/Level Inspection

Pre-ride Pre-ride Replace engine coolant

every two years Fuel and oil tanks Pre-ride Pre-ride Fill to proper levels Throttle Pre-ride Pre-ride Check operation Lights Pre-ride Pre-ride Check operation Engine Stop Switch Pre-ride Pre-ride Check operation Drive Chain Pre-ride Pre-ride Condition and Slack Steering Pre-ride Pre-ride Check for free operation

" Air Box Sediment

Tube

Pre-ride Pre-ride Drain deposits whenever

visible Headlamp Inspection Pre-ride Pre-ride Check operation daily; ap-

ply Polaris dielectric

grease to c onnector when

replaced Tail lamp inspection Pre-ride Pre-ride Check operation daily; ap-

ply Polaris dielectric

grease to socket when re-

placed

"LAirFilter-MainEle-

ment

Weekly Weekly Inspect-Replace if neces-

sary

Page 93

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

Item Hours or

Miles

When Remarks

" Transmission Oil

Level

20 hrs Monthly Inspect monthly; change

annually

Battery 20 hrs Monthly Check Terminals/clean/

check fluid level

Engine Counterbalance (400 Engines)

20 hrs Monthly Check oil level; change

annually

"LEngine breather filter

(4-cycle)

20 hrs Monthly Inspect--replace annually

and as needed

J Brake pad wear 10 hrs Monthly Inspect periodically " Front and Rear Gear-

case Oil (shaft drive)

100 hrs Monthly Check monthly and

change annually

Engine Cylinder Head and Cylinder Base Fasteners

25 hrs 3

months

Inspect (re-torque required at first service only)

" General Lubrication 50 hrs 3

months

Lubricate all fittings, pivots, cables, etc.

"LEngine Oil - Level/

Change (4-Cycle)

100 hrs / 1000 miles

6 months

Check Level Daily; Break in Service at 1 month. Change oil more often in cold weather use.

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

CAUTION

Page 94

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles

When Remarks

"LOil Filter(4-Cycle) 100 hrs /

1000 miles

6 months

Replace with oil change

Oil Pump Cable (2-Cycle)

50 hrs 6

months

Inspect, adjust, lubricate,

replace if required

L Engine breather

hose (4-cycle)

100 hrs 6

months

Inspect

Carburetor Float Bowl

50 hrs 6

months

Drain bowl periodically and

prior to storage

J Throttle Cable/ETC

Switch

50 hrs 6

months

Inspect-adjust, lubricate,

replace if necessary; pre-

ride inspection item

L Choke (Enricher)

Cable

50 hrs 6

months

Inspect-adjust, lubricate,

replace if necessary Coolant strength/

pressure test system

100 hrs 6

months

Inspect strength seasonal-

ly; pressure test system

annually

" Front hubs/fluid

check (AWD)

50 hrs 6

months

Check monthly

Shift linkage 50 hrs 6

months

Inspect, adjust

J Drive belt 50 hrs 6

months

Inspect, replace if neces-

sary

" Steering 50 hrs 6

months

Inspect daily, lubricate

" Front Suspension 50 hrs 6

months

Inspect--lubricate, tighten

fasteners

" Rear Suspension 50 hrs 6

months

Inspect, tighten fasteners

" Drive Chain(s) 50 hrs 6

months

Inspect daily, adjust and

lubricate if needed

L Spark Plug 100 hrs 12

months

Inspect--replace if neces-

sary

" Rear Axle 50 hrs 6

months

Inspect bearings, Lube

Page 95

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

Item Hours or

Miles

When Remarks

JLIgnition Timing 100 hrs 12

months

Inspect and adjust as needed

JLFuel System 100

hours

12 months

Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.

J Fuel Filter 100 hrs 12

months

Replace annually

Radiator 100 hrs 12

months

Inspect/c lean external surface

Cooling System hoses

100 hrs 12

months

Inspect

Spark arrestor 100 hrs 12

months

Clean out

" Front hubs/fluid

change (AWD)

100 hrs 12

months

J Clutches (drive and

driven)

100 hrs 12

months

Inspect, clean

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

CAUTION

Page 96

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles

When Remarks

Engine Mounts 100 hrs 12

months

Inspect

JLValve Clearance

(4-Cycle)

100 hrs 12

months

Inspect/Adjust

J Injector Oil Filter

(2-Cycle)

100 hrs 12

months

Replace

J Shift selector box (H/

L/R)

200 hrs 24

months

Change lubricant every

two y ears

J Brake fluid 200 hrs 24

months

Change every two years

J Front wheel bearings

(2wd)

300 hrs 36

months

Inspect, replace if neces-

sary

L Idle Speed As Re-

quired

As Required

Adjust

Recoil housing As re-

quired

As required

Drain moisture out after

riding in water

J Toe adjustment As re-

quired

As required

Periodic inspection, adjust

when parts are replaced Headlight Aim As re-

quired

As required

Adjust if necessary

Page 97

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Rec Method Frequency*

1. Engine Oil (2-Cycle)

Polaris Injection Oil

Fill oil tank. See page 49. As needed,

when refueling

2.Engine OIl (4-Cycle)

Polaris Premium 4 Synthetic 0W40

Add to proper level on dipstick. See page 105.

Check level daily.

3. Brake Fluid

DOT 3 Only

Maintain level between fill lines. See page 46.

As required; change every two years or 200 hours

4. Transmission Oil

Polaris Premium Synthetic gear case lube

See Page 117 Change

annually or at 100 hours

5. Front Gearcase Oil

GL5 80-90 Weight Gear Lube

See Page 122 *Models with Visco drive require special lubricant. See your owner’s manual supplement for requirement.

Change annually or at 100 hours

6. Front Prop Shaft U-joints

Grease+ Locate Fittings and

Grease

Every 3 months or 50 hours

7. Front Propshaft Yoke

Grease+ Locate fittings and grease

-- 3 pumps maximum

Every 3 months or 50 hours

8. Drive Chain(s)

O-Ring chain lube or SAE 80/90

Lubricate as often as required. Before each ride in wet conditions

As required

9. Demand 4 Hubs - All Wheel Drive ATVs

Premium Hub Lube

Remove set screw in hubs. Rotate wheels to 4 O’clock position. If lubricant is not visible add more. Reinstall set screw.

Annually or at 100 hrs

Page 98

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Operating Range

Full

4. Transmission (dipstick)

6. Front Prop Shaft (U-Joint)

Fill plug

5. Front Gear Case

4. Transmission (plug)

7. Propshaft Yoke

Fill plug

Page 99

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

10. Front Drive Axle (U Joint) (AWD Models)

Grease+ Locate grease fitting and

grease with grease gun.

Every 3 months or 50 hours

11. Ball Joint L Grease **

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

Every 3 months or 50 hours

12. Front A

Arm Pivot Shaft

Grease **∆

Locate fitting on pivot shaft and grease with grease gun.

Every 3 months or 50 hours

13. Counter

Balance Housing (400)

SAE 10/30

Check level on dipstick and add oil as necessary. Change annually . To change oil see page 125.

Check monthly and change annually

14. Upper

steering Post Bushing

Grease **

Locate fitting on steering post and grease with grease gun.

Every 3 months or 50 hours

Page 100

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

10. Axle Cardan Front Drive (AWD Models)

13. Counterbalance Dipstick

14. Steering Post Bushing

11. Ball Joint

12. Front A-Arm Pivot Shaft

Upper

9. 4 O’clock position

9. Demand 4 Hubs (4x4 only)