Polaris ATV Sportsman 400 HO User Manual

Download

Sportsman 400 H.O.

Owner's Manual

for Maintenance and Safety

Read this manual carefully. It contains important safety information.

Operation is prohibited for those under 16 years of age.

This is an adult vehicle only.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800342-3764 for assistance.

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

•RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Yo ur manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

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

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A. 2014 SPORTSMAN 400 H.O. / 400 H.O. SE Owner’s Manual P/N 9924247

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

WARNING

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

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

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

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

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

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was

controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on

many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

INTRODUCTION

####

Engine Serial Number

Key Number

VIN

(front or rear frame)

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

SAFETY

Safety Training

ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course.

If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse available to you and your eligible family members. This training is included in the purchase price of your ATV. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used POLARIS ATV in the United States, you can

enroll in the ATV RiderCourse

for a fee. Call ATV Enrollment

Express at (800) 887-2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the United States, please

contact your dealer or local law enforcement agencies for information about safety training.

A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

W e strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.

that is

SAFETY

Safe Riding Gear

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

Eye Protection

Gloves

Long Pants

Boots

Helmet

Long

Sleeves

Helmet

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

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

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

051039

0006.31

number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Equipment Modifications

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

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

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

SAFETY

WARNING

Safety Warnings

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

Operating Without Instruction

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

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

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

Age Restrictions

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

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

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

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

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

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident.

Always inspect the ATV before each use to make sure it's in safe operating condition.

Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

SAFETY

Safety Warnings

Protective Apparel

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

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

Using Alcohol or Drugs

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

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

Carrying a Passenger

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

Never carry a passenger on this ATV.

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.

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

Operating on Public Roads

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

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

Operating at Excessive Speeds

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

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

SAFETY

Safety Warnings

Physical Control of the ATV

Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the AT V. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.

Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn.

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

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

Jumps and Stunts

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

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

Improper Hill Climbing

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

SAFETY

Safety Warnings

Descending Hills Improperly

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

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

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

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

Crossing Hillsides

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

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

Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 54.

SAFETY

Safety Warnings

Stalling While Climbing a Hill

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

• Always maintain a steady speed when climbing a hill.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the brakes.

• Lock the parking brake when fully stopped.

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

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

If the ATV begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

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

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

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

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

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn.

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

Safety Warnings

Operating on Slippery Terrain

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

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

Operating in Unfamiliar Terrain

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

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

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

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 57.

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

Improper Tire Maintenance

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

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

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

Operating Over Obstacles

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

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

Skidding or Sliding

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

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

SAFETY

Safety Warnings

Operating Through Deep Water

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

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

55):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or

stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the

brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

Improper Cargo Loading

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

• Never exceed the stated load capacity for this ATV.

• Cargo should be properly distributed and securely attached.

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

distance for braking.

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

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

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

pulling a trailer. See page 59.

SAFETY

Safety Warnings

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice.

Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party. Varian ces in snow dep th and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. ATV operators assume all risk associated with ice conditions on frozen bodies of water.

Poor Visibility

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

Operating a Damaged ATV

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

Physical Skills

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

Hot Exhaust Systems

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

Unauthorized Use of the ATV

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

SAFETY

Safety Decals and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

General Warning

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk

of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough

terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

SAFETY

Discretionary

Warning

Safety Decals and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.

• REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

7175511

Tire Pressure/Load Warning

WARNING

Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

• Cold tire pressure:

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

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

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

7177973

Hitch Capacity Label

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

7174159

“No Passenger” Warning

WARNING

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

DEATH.

Age 16 Warning

WARNING

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

NEVER operate this ATV if you are under age 16.

7175378

7175374

Safety Decals and Locations

SAFETY

General Warning

Rack

Warning

Age 16

Warning

“No Passenger”

Warning

Rack

Warning

Hitch

Capacity

Clutch Cover

Warning

Tire Pressure/Load

Warning

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or death.

NO STEP

7172563

Rack Warning, Front and Rear

WARNING

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

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

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

7172572

Reverse Override Warning/4X4 Caution

WARNING

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

7175486

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

Choke

AWD Switch

Switches

Mode/Reverse Override Switch

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

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

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

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

is in reverse.

AWD Switch

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

FEATURES AND CONTROLS

Switches

Engine Stop Switch

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

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

Main Key Switch

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

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.

OFF OFFRUN

FEATURES AND CONTROLS

WARNING

Throttle Lever

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

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

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

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

This ATV is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine wil l stop , and power to the rear wheels will cease.

FEATURES AND CONTROLS

WARNING

Brake Lever

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

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

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

FEATURES AND CONTROLS

WARNING

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

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

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

Check the brake fluid in the master cylinder before each ride.

1. Position the ATV on a level

surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

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

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

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

lever. It will return to its unlocked position.

WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

WARNING

Auxiliary Foot Brake

Foot Brake Fluid

Reservoir

Auxiliary Foot Brake

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

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

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

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

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

Brake Fluid Level

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

FEATURES AND CONTROLS

OFF

Fuel

Tank

Cap

Fuel

Valve

Fuel Valve

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

OFF: For vehicle storage and when transporting.

ON: For normal operation.

Choke

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

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter.

Fuel Tank Cap

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

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

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

percent, such as E-85 fuel.

FEATURES AND CONTROLS

Gear

Selector

Automatic Transmission Gear Selector

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

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

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is

Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.

Belt Life

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

moving could cause transmission damage.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

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

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

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

is on. See page 24.

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

Engaging A WD

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

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

AWD

Switch

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

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

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

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

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

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

FEATURES AND CONTROLS

345

Instrument Cluster

Rider Information Center

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

1. Gear Indicator - This

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

2. AWD Indicator - This

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

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

6. Odometer/Tachometer/Tripmeter/ Hour Meter

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

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

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

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

9. Mode Indicator

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

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

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

The trip meter records the miles traveled by the ATV on each trip if it's reset before each trip. T o reset the trip meter , select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

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

Gear Circuit Diagnostic Screen

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

Programmable service interval

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

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

until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

OPERATION

WARNING

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

Break-In Period

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

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

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

OPERATION

Break-In Period

Engine and Drivetrain Break-in

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

extreme caution whenever handling gasoline.

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

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

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

familiarize yourself with vehicle operation and handling.

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

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

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

6. Pull only light loads.

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

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

hours of operation and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

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

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

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

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

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

3. Never carry a passenger on this ATV.

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

run in an enclosed area.

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

emergency situations (if service brakes become inoperable).

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

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

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

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

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

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

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

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

Always maintain proper tire pressure.

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

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

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

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

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

combustible materials away from the exhaust system.

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

prevent unauthorized use.

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow . T read lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

OPERATION

Pre-Ride Checklist

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

Item Remarks Page

Brake system/lever travel Ensure proper operation 27 Brake fluid Ensure proper level 28

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

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

Coolant level (if applicable) Ensure proper level 88 Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 26 Indicator lights/switches Ensure operation 24

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

Brake light/taillight Check operation, apply POLARIS

Riding gear Wear approved helmet, goggles, and

dielectric grease when lamp is replaced

protective clothing

81 89

117

25 98

101

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-

ventilated area.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

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

choke can cause the spark plug to become wet fouled.

7. If the engine is cold, pull the

choke knob out until it stops.

Tip: The variable choke is fully on

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

8. If the knob doesn't stay where

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

9. Move the engine stop switch to RUN.

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

Tension

Adjusting Nut

OPERATION

Starting the Engine

11. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

12. If the engine does not start, return the key to the OFF position and

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

13. If the engine slows or stops, position the choke knob half way in to

Cold Weather Operation

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

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

wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

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

allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

OPERATION

Driving Procedures

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

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

handlebars.

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

4. Shift the transmission into gear.

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

6. Release the parking brake.

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

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

brakes on level surfaces.

OPERATION

Turning the Vehicle

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

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

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

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

OPERATION

Driving on Slippery Surfaces

Sideways

skid

Turn in direction

of skid

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

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

2. Slow down when entering slippery areas.

3. Engage AWD before wheels begin to lose traction.

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

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

4. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

5. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body weight forward.

OPERATION

Driving Uphill

25° Maximum

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

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

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

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

5. Keep both feet on the footrests.

6. Shift your weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

8. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

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

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

possible, or dismount on the uphill side immediately!

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Shift body weight uphill.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause

loss of control.

5. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of control.

OPERATION

Turning Around on a Hill (K-Turn)

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

8 ft. (2.4 m)

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

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

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

vehicle is pointing straight uphill.

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

5. While holding the brake lever, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

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

keeping body weight uphill.

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

8. Release the parking brake and proceed slowly , controlling speed

with the brake lever, until the vehicle is on more level ground.

OPERATION

Driving Through Water

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

1. Determine water depths and

current before entering water.

2. Choose a crossing where

both banks have gradual inclines.

3. Avoid operating through

deep or fast-flowing water.

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

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

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 104, then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several

times while driving slowly. The friction will help dry out the pads.

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly . Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

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

Do not make sudden throttle changes.

Maximum

Depth

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for

hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override button unless additional wheel speed is

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine damage.

OPERATION

WARNING

Hauling Cargo

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

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

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

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

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

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

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

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

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

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

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

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

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

OPERATION

1/3

2/3

Maximum

4" (10 cm)

Hauling Cargo

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

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

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

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

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

belt life.

Towing Loads

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

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

not exceed the rear rack capacity.

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

not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding

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

OPERATION

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

5. Turn the fuel valve off.

WINCH GUIDE

WARNING

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

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

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

Winch Safety Precautions

1. Read all sections of this manual.

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

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

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

winch.

5. Always keep body, hair, clothing and jewelry clear of the winch

cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving

vehicle. See the Shock Loading section on page 70.

7. Always keep the area around the vehicle, winch, winch cable and

load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch

are not being used.

9. Always be sure that at least five (5) full turns of winch cable are

wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to

hold the vehicle in place during winching. Use wheel chocks if needed.

WINCH GUIDE

Winch Safety Precautions

11. Always align the vehicle and winch with the load directly in front of

the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.

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

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

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

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

and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the

winching vehicle and possibly cause it to move without warning.

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

rated capacity.

15. The winch motor may become hot during winch use. If you winch

for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the

winch cable while winching a load.

17. Never let the winch cable run through

your hands, even if wearing heavy gloves.

18. Never release the clutch on the winch

when the winch cable is under load.

19. Never use the winch for lifting or

transporting people.

WINCH GUIDE

Winch Safety Precautions

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

21. Never immerse or submerse your winch in water. Take your winch

to your dealer for service if this occurs.

22. Always inspe ct your winch and winch cable before each use.

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

to winch components.

24. Unplug the remote control from the vehicle when the winch is not in

use to prevent inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable

to collect debris that will shorten the life of the cable.

WINCH GUIDE

WARNING

Hook Strap

Winch Operation

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

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

need to use it in the field.

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

Each winching situation is unique.

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

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may nee d to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

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

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

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

damaged cable.

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

3. Always apply your vehicle’s

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

WINCH GUIDE

NO YES

Winch Operation

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

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

A. Attach the hook itself onto the

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

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

stretch.

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

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

winch cable and may result in winch cable failure.

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

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

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

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

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

E. Before operating the winch , be sure

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

F. Never operate your winch with a

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

YES

WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

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

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

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

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

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

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

spooled out.

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

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

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

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

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

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

WINCH GUIDE

Winch Operation

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

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

cable.

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

centerline.

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

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

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

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

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

instructions in this manual.

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

WINCH GUIDE

Winch Operation

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

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

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

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

kg) of tension using the hook strap.

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

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

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

between lower layers of winch cable.

WINCH GUIDE

Winch Cable Care

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

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

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

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

or kinked winch cable.

A. A kinked winch cable made of

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

B. A kinked winch cable made of

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

C. A winch cable made of

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

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

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

WINCH GUIDE

Shock Loading

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

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

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

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

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

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

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

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

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

WINCH GUIDE

Shock Loading

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

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

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

WINCH GUIDE

Winch Maintenance and Service Safety

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

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

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

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

winch.

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

connections to prevent accidental activation of the winch

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

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

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

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

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

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

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

EMISSION CONTROL SYSTEMS

Emissions Label

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are sub ject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at POLARIS specifications to achieve optimal performance.

Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjustments should be performed by an authorized POLARIS dealer.

The emissions label is located on the right frame tube.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with

active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

MAINTENANCE

Periodic Maintenance Chart

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

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on page 141.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Symbol Description

Ź Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (failure to conduct this maintenance will not void

the emissions warranty but may affect emissions)

D Have an authorized POLARIS dealer perform these services.

WARNING! Improperly perform ing the procedures marked with a “D” could

result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

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

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

Ź Air box sediment

tube Coolant - Daily - Check level daily, change

Headlight/taillight/ worklight

Air filter, main

element Recoil housing - Weekly - Drain water as needed,

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

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

Engine breather

filter (if equipped)

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

(if equipped)

Ź Transmission oil 25 H 1 M 250 (400) Break-in oil level check

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

Pre-Ride

- Daily - Drain deposits when visible

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

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

25 H 1 M 250 (400) Break-in oil level check

(Km)

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

as needed

coolant every 2 years

dielectric grease if replacing lamps

check often if operating in wet conditions

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

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

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

D Steering 50 H 6 M 310 (500) Lubricate

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

Carburetor float bowl

DEThrottle Cable/

Release Switch

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

E Carburetor air

intake ducts/flange Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

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

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

fasteners

Ź Demand drive fluid

(normal use)

Ź Rear gearcase oil

(if equipped)

Ź Transmission oil 100 H 12 M 1000 (1600) Change fluid

DEValve clearance 100 H 12 M 1000 (1600) Inspect; adjust

(whichever comes first)

Hours Calendar Miles

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

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

50 H 6 M 500 (800) Inspect duct for proper seal-

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

100 H 12 M 1000 (1600) Change fluid

(Km)

cables, etc.

prior to storage

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

fittings

Remarks

DEFuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

Ź Radiator (if

applicable)

Ź Cooling hoses (if

applicable)

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

Exhaust muffler/ pipe

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

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

lines, fuel valve, filter, pump, carburetor; replace lines every two years

surfaces

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

DESpark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

DEIgnition timing 100 H 12 M 1000 (1600) Inspect

Ź Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

D Clutches (drive

and driven)

D Front wheel

bearings

D Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrester 300 H 36 M 3000 (4800) Clean out Idle speed - Adjust as needed

D Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

(Km)

security; apply dielectric grease to connectors subjected to water, mud, etc.

parts

when parts are replaced

Remarks

MAINTENANCE

Lubrication Guide

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

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

Item Lube Capacity at

Engine Oil PS-4 5W-50

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

Transmission Oil AGL Gearcase

Demand Drive Fluid (Front Gearcase)

Front Prop Shaft Yoke

4-Cycle Oil

Lubricant & Transmission Fluid

Demand Drive Fluid

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

Fluid Change

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

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

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

Inspection Procedure

on dipstick. See page 81.

lines. See page 28.

hole threads. See page 85.

hole threads. See page 86.

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

Front Prop Shaft Yoke

MAINTENANCE

Engine Oil

Oil Recommendations

Lubricant Capacity Drain Plug Torque

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

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

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

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Engine Oil

Dipstick

Safe

Add Oil

{

Safe Range

Oil Level

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

A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the engine.

3. Remove the dipstick. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

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

MAINTENANCE

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

Oil and Filter Change

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

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the oil tank.

6. Remove the drain plug. Allow the oil to drain completely.

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

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

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

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

PST 505 or PTFE seal tape.

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

11. Reattach the oil line.

MAINTENANCE

Oil and Filter Change

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

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

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

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

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

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

18. Rem ove the dipstick.

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

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

20. Place the transmission in PARK.

21. Loc k the parking brake.

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

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

24. Dispose of used filter and oil properly.

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

(5 cm)

Oil and Filter Change

Oil Pump Priming

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

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

2. Start the engine. Allow it to idle

for 10-20 seconds.

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

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

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

MAINTENANCE

Fill

Level

Fill Plug

Transmission Oil

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

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

Fill Plug

Transmission Oil Recommendations

Lubricant C apacity Fill Plug

AGL Gearcase Lubricant &

Transmission Fluid

32 oz.

(946 ml)

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the

oil level.

3. Add the recommended fluid as

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

4. Reinstall the fill plug. Torque to

specification.

Torque

20-25 ft. lbs.

(27-34 Nm)

Drain Plug

Torque

20-25 ft. lbs.

(27-34 Nm)

MAINTENANCE

Drain Plug

Fill

Plug

Fill Level

Transmission Oil

Oil Change

1. Remove the fill plug.

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

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

4. Add the proper amount of the recommended oil.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Dispose of used oil properly.

Front Gearcase (Demand Drive) Fluid

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

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Front

Gearcase

Demand Drive Fluid 9 oz.

(265 ml)

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

Torque

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

Drain Plug

Torque

11 ft. lbs.

(15 Nm)

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Check

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

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

level to the bottom of the fill hole threads.

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

Fluid Change

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

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

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

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

fluid level at the bottom of the fill hole threads.

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

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

MAINTENANCE

Cooling System

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

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

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

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

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

Recovery Bottle Coolant

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

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

2. Maintain the coolant level

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

3. Add coolant as needed.

Recovery

Bottle

MAINTENANCE

Cooling System

Radiator Coolant

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

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

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

1. Open the front box cover.

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

3. Remove the pressure cap.

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

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

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

Radiator

Cap

MAINTENANCE

3/64" (1 mm)

Brakes

Hand Brake

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

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

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

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 28.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

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

5. Check the security and surface condition

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

Auxiliary Foot Brake

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

MAINTENANCE

Toe Alignment

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

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

1. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

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

4. Measure the distance

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

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

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

service.

Stand

String

FRONT

MAINTENANCE

Screws

Rivets

Steering Assembly

The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

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

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

Step 1 Step 2 Step 3

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

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

3. Remove the footwell.

MAINTENANCE

WARNING

Tires

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

Refer to the specifications section beginning on page 130 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

WARNING! Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer.

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

6. Remove the wheel nuts.

7. Remove the wheel.

1/8" (3 mm)

MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in PARK.

2. Lock the parking brake.

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

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

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

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

Wheel Nut Torque Specifications

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

Nut Type Nut Torque

Lug Nut (Aluminum Wheels)

2-Piece Flange Nut (Steel Wheels)

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

27 ft. lbs. (37 Nm)

MAINTENANCE

Main Filter

Pre-Filter

Breather

Filter

Air Filter

1. Remove the seat.

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

3. Loosen the clamp and remove the filter.

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

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

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

7. Reinstall the air box cover and the seat.

MAINTENANCE

Breather Filter/Hose

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

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

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

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

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

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

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

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

Fuse Replacement

Fuse Panel

Fuses

5or61520 20

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

1. Open the front box cover.

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

3. Secure the front box cover.

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.

Headlight Lamp Replacement

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

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

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

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

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

the speedometer.

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

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

connector, not on the wiring.

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

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

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

8. Reassemble the pod.

Polaris ATV Sportsman 400 HO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual