Polaris ATV 2002 Owner's Manual
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.
Indicates a potential hazard that could result in serious
injury or death.
WARNING
1
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2
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.
Copyright 2001
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.
3
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.
4
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...............................
5
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...........................
6
VEHICLE IDENTIFICATION NUMBERS
2
1
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
7
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
8
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.
9
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.
10
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.
11
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.
12
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.
1
13
SAFETY
Safety Decals and Locations
1
7079083
E1997, 2000
IF OWNER’S MANUAL IS MISSING, CONT ACT
YOUR POLARIS DEALER FOR A REPLACEMENT.
WARNING
14
SAFETY
Safety Decals and Locations
2
3
15
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
2
3
WARNING
WARNING
16
SAFETY
Safety Decals and Locations
4
5
6
17
SAFETY
Safety Decals and Locations
4
5
(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)
6
WARNING
18
SAFETY
Safety Decals and Locations
7
8
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)
7
8
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
19
SAFETY
Safety Decals and Locations
9
9
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
9
WARNING
20
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.
21
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.
1
2
3
4
5
22
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
WARNING
23
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
24
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
25
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
26
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
27
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
WARNING
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